Capsule filling machines are essential for pharmaceutical, nutraceutical, and supplement manufacturers looking to produce capsules efficiently and accurately. Whether you’re a large-scale producer or a small business, choosing the right machine can significantly impact your production capacity, product quality, and operational efficiency.

In this guide, we’ll answer key questions about capsule filling machines, including their types, how to choose the right one, essential maintenance tips, and factors to consider when making a purchase. If you’re looking to improve your capsule production process or invest in a new machine, this article will provide the insights you need.

1. What is a capsule filling machine, and why is it important?

A capsule filling machine, also known as an encapsulating machine or capsule filler, is a device used to fill empty capsules with materials such as powders, granules, liquids, or semi-liquids. It plays a crucial role in industries like pharmaceuticals, food, and chemicals by ensuring precise dosage, improving efficiency, and maintaining high product quality. Modern capsule filling machines can produce up to 450,000 capsules per hour, streamlining production processes while maintaining strict regulatory standards.

2. What are the different types of capsule filling machines, and which one should I choose?

Capsule filling machines are available in three primary types, each suited to different production needs:

1. Automatic capsule filling machines:
   • Features: Fully automated and designed for all levels of production, these machines can fill from 25,200 – 450,000 capsules per hour.
   • Benefits: High accuracy, user-friendly design, easy maintenance, and continuous production.
     
     • Lower relative labor cost compared to semi-automatic machines as the same operator can produce more capsules on a high capacity automatic machine than a semi automatic machine.
   • Best for: Large pharmaceutical companies with multiple production lines.
     
2. Semi-automatic capsule filling machines:
   • Features: Combines manual and automated operations, capable of filling 20,000–47,000 capsules per hour. However this does depend on the capability of your labor force to efficiently operate the machine and follow the process.
   • Benefits: Accurate filling, power efficiency, quick operation, and easy upgrades.
   • Best for: small-scale production with varied formulations.
3. Manual capsule filling machines:
   • Features: Fully operated by hand, these machines fill approximately 300 capsules per cycle.
   • Benefits: Cost-effective, easy to use, and reduced material wastage.
   • Best for: Small-scale production and budget-conscious users.

3) How do I select the correct capsule size for my needs?

Common Capsule sizes range from 000 (largest) to 5 (smallest). The choice depends on the required dosage and ease of swallowing:

• Popular sizes: 00 to 2 are commonly used due to their balance of volume and swallowing comfort.
• Volume capacity: Capsules vary in capacity, with 000 holding up to 1.37ml and size 5 holding 0.13ml.
• Formulation density: The material density impacts the weight capacity of the capsule. Consult size charts for precise volume-to-weight conversions.

*The data above apply to the most common hard gelatin capsule at a moisture content of 13-16% w/w. Other types of capsules are also available for further inquiry.

4) How can I maintain a budget when purchasing a capsule filling machine?

Balancing quality and cost is essential:

• Evaluate your production needs: Choose a machine type (semi-automatic, or automatic provided by Encap North America) based on output requirements.
• Long-term investment: Higher upfront costs for automatic machines may yield savings through increased productivity and reduced downtime.
• Vendor consultation: Work closely with your vendor to find a machine that meets your quality and budget requirements without compromising efficiency.

5) What maintenance is required for a capsule filling machine?

Proper maintenance ensures longevity and consistent performance:

• Daily cleaning: Use a nylon brush to clean powder-contact parts and wipe grease lines. Avoid leaving powders in the machine overnight.
• Lubrication: Periodically lubricate moving parts to prevent wear and tear.
• Vacuum filter care: Clean the filter regularly for optimal performance.
• Parts replacement: Inspect and replace worn parts as needed.
• Prohibited practices: Do not use hot water, corrosive liquids, or heating appliances to clean the machine. These can damage components and reduce the machine’s lifespan.

6) What are the key components of an automatic capsule filling machine?

A Capsule Filling Machine has a number of major components and each has its own distinguished purpose.

1. Capsule Hopper: Where we load empty capsules. Capsule Hopper is equipped with a sensor which triggers an alarm when the hopper is almost empty. It may pair with an Automatic Capsule Loading machine to streamline the process.
2. Capsule Separating Station: Capsule Separate Station includes capsule magazine, vertical fork, and horizontal fork. It utilizes compressed air to separate and align capsules.
3. Rotary Disc: This rotating disc carries (ten) sets of capsule segments. Efficiently transport the perfectly aligned capsules to the upcoming stations for filling, tamping and locking.
4. Powder Hopper: Where we load powder, pellet or other component into the Tamping Station. Powder Hopper includes a feeding motor and a feeding spiral for consistent feeding. Combine with a Vacuum Powder Loading Machine to save you more time.
5. Tamping Station: Tamping Station includes a dosing disc, six sets of taming pins, a sensor and other mechanism for the tamping and filling. Unique design to fill the capsule with precise dosage and to eliminate product waste.
6. Reject Station: Rejection of defected capsules, unseparated capsules to ensure high batch quality.
7. Capsule Locking Station: To close the filled capsules.
8. Discharge Station: To eject filled capsules and send them to Capsule Polisher for final touch.
9. Cleaning Station: Compressed air comes out of Vent Pins to efficiently clean the segments for the next working cycle.
10. Transmission System: The Transmission system is located in the lower part of the machine. It includes a finely designed motor and cam index gear box etc.
11. Electronic Control System: HMI (Human Machine Interface) is easy to operate and set up the machine.

Additional Key Elements to the capsule filling machine include:

• Dosing Disks: Essential for precise dosing of powders, granules, or pellets into capsules.
• Tamping Pins: Compresses the powder into uniform doses within the dosing disk.
• Capsule Magazine: Ensures the capsule is positioned correctly before filling and delivers a steady supply during operation.
• Capsule Locking Mechanisms: Used to seal the capsules after filling.
• Vacuum Pump Filters: Integral for the vacuum system, which helps position and seal the capsules.
• Control Panels and Sensors: Ensure the machine operates at optimal settings.
• Lubrication Components: help to keep the capsule filling machine running smoothly.  These include, the cam, bearings, chain, gears and cam indexer gear box.
• Capsule Segments: holds and aligns the capsules during the filling process.
• Motors and Gear Systems: drives the various automated processes in the machine.
• Hopper and Feeding Spiral: feeds the material consistently into the dosing mechanism.
• Sealing Rings and Gaskets: maintain airtight seals in various parts of the machine.
• Ejector Pins: pushes the filled capsules out of the machine.
• Filters for Dust Collectors: captures material dust and waste capsules during operation.

Regular maintenance and timely replacement of these parts ensures smooth operations and prevents costly downtime. We provide ongoing support and consultation to help with any queries or questions you may have about spare parts, replacement and maintenance.

7) What Accessories do you typically need when running an Automatic Capsule Filling Machine??

Accessories: There are a number of key add-on machines or devices that enhance the performance of the Automatic Capsule Filling Machine- which may be purchased separately.

• Capsule Loading Machine
• Capsule Sorting Polisher (Horizontal/ Vertical)
• Vacuum Loading Machine
• Automatic Capsule Separating Machine
• Dust Collector
• Different size of mould if needed

Spare Parts: There are some key parts that need to be checked or replaced after a certain period of time. Some of these are included in the initial purchase and will need to be reordered and purchased separately as time goes by.

• Bearings
• Seals
• Shafts
• Spring
• Filter
• Capsule Sized Changing Segment

8) What factors should I consider when choosing a capsule filling machine?

Key considerations include:

1. Production requirements: scale of production (small, medium, or large) and therefore your capacity requirement
2. Automatic or semi-automatic?: Automatic machines are ideal for high-volume production, while semi automatic machines suit smaller operations. (lower capacity and investment).
3. Material being used to fill the capsule: powder, pellets and oil can all be used with our capsule filling machines
4. Machine dimensions and weight: Consider your production environment so that the machine can be installed and will function properly without issue.
5. Customization: Look for machines that can be modified to meet specific production needs.

   At Encap North America, we can provide bespoke modifications at the scoping stage to ensure your machines meet your specific needs. We always recommend doing these modifications at the outset.

6. Cost: Ensure the machine fits your budget without compromising on quality or features.

9) How long should you expect a new automatic capsule filling machine to last for?

A new automatic capsule filling machine can typically last 10–15 years or even longer with proper care and maintenance. The lifespan depends on several factors, including the quality of the machine, the intensity of use, and adherence to recommended maintenance practices.

Factors Influencing Longevity:

1. Build Quality:
   Our machines are constructed with high-quality materials, such as stainless steel, and designed for pharmaceutical-grade standards tend to last longer.Reputable manufacturers such as those represented by Encap North America provide machines with durable components that withstand continuous operation.
2. Frequency of Use:
   Machines running in high-capacity environments with 24/7 operations will require more levels of planned maintenance.
3. Maintenance Routine:
   Regular cleaning, lubrication, and replacement of worn parts are essential to prevent excessive wear and tear.Following the manufacturer’s maintenance schedule can extend the machine’s longevity by several years.
4. Operating Conditions:
   Machines used in clean and controlled environments are less likely to degrade prematurely. Suggested working temperature at 21℃ ± 3℃ and working relative humidity at 40～55%.Exposure to dust, moisture, or corrosive materials can accelerate wear.
5. Operator Expertise:
   Proper training ensures operators handle the machine correctly, reducing the risk of damage due to misuse.

Tips to Maximize Machine Performance:

• Conduct regular inspections to identify and address issues early.
• Use high-quality, compatible spare parts for replacements – such as those supplied by Encap North America.
• Ensure the machine operates within its capacity limits to avoid undue stress.
• Maintain a strict cleaning routine to prevent material buildup and corrosion.
• Periodically calibrate the machine for precision and efficiency.
• Ensure proper tamping pressure on tamping pins instead of too heavy or too high pressure – if done incorrectly, your tamping pin guider may be damaged.
• Ensure you have properly trained operators. Here at Encap, we offer comprehensive training and support to our customers which means their machines run for longer, saving money in the long term.

By investing in a high-quality machine and adhering to proper care practices, you can ensure reliable performance and maximize the return on your investment over its operational life. Watch this video below and see how our happy customers are using machines supplied from Encap North America over ten years after they have purchased from us.

10) Where can I buy a cost-effective and reliable capsule filling machine?