In the world of packaging machinery, it may seem odd to refer to a diverse range of products like baking mixes, ground coffee, spices, and powdered sugar simply as "powders." However, regardless of the industry, producers share similar priorities when it comes to evaluating packaging solutions for their products.
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When it comes to selecting packaging equipment for your free-flowing powder product, the sheer number of models and brands available can be overwhelming. However, before diving into the comparison of run rates, technical features, and bag styles, it is essential to determine which factors are truly crucial for your business. Automation, accuracy, accessibility, and long-term support are some of the key considerations that can greatly impact the long-term success of your operation.
The importance and prioritization of these categories may vary depending on the type of product and your specific performance needs. Nevertheless, they all play a vital role in ensuring the efficiency and sustainability of your business.
High Automation for High OEE
When selecting a powder filling machine, one of the primary considerations is the level of automation required to streamline production. Some auger filling machines are designed with advanced automation capabilities, while others offer more manual operation features. If you have a low current volume and staffing is not a pressing concern, investing in a highly automated solution may not provide a justifiable return. However, if you are aiming for higher output, automation will significantly impact your overall performance.
Automated filling components, though not exclusive to powder filling, are particularly well-suited for high-volume operations. These machines often boast advanced features that enable you to accomplish more with fewer labor resources. For instance, certain models offer hands-free washdown capabilities or the ability to adjust auger screw rotation based on measured weight or volume, reducing the need for constant monitoring by operators. This level of automation proves invaluable in high-speed operations where precision is paramount, thus leading us to the next evaluation category: filling accuracy.
Filling Accuracy
The higher the value of your powder product, the higher that filling accuracy is going to fall on your list of priorities. Powder packing filling accuracy can be tricky, because even environmental factors can affect the density of the product being fed to your filling component.
For example, humidity level changes from day to day can change how dense a powdered product will become at room temperature. Temperature fluctuations throughout shifts can cause similar problems- so to avoid having quality issues with low-accuracy machine components, it&#;s important to choose products that are built to adapt as the production environment fluctuates.
These machines can be fully integrated with the bagger to include auxiliary sensors to monitor fill weights and can adjust settings automatically, minimizing variance in density across different powders. Accurate powder filling machines help ensure that end-users do not experience quality issues due to too much variance in overall powder weight percentage and help you to minimize product giveaway.
Powder Filling Machine Accessibility
A third crucial factor to consider when evaluating powder packaging solutions is the level of accessibility. What is packaging machine accessibility? This is the level at which operators and maintenance people can visually and/or manually gain access to a variety of components on their machinery, as needed. This can be anything from the electrical components, to the product in the machine.
High machine accessibility ultimately translates to shorter periods of downtime for washdown, which saves you money. It&#;s important that maintenance tasks are not only easy but also safe so they can be carried out effectively shift after shift, year after year.
There are a variety of solutions available to help your operation meet hygiene and automation requirements and allow for faster changeovers. ROVEMA auger fillers are available with automated, chemical-free washdown systems as well as a split door hopper that allows for easy cleaning and maintenance and also feature a window on the side of the hopper to allow operators to monitor the product.
Tech Support and Long Term Customer Experience
When you invest in capital equipment that you plan to have for decades, it's crucial to have a thorough understanding of what your overall experience will be like when issues arise. It's not enough to simply purchase high-quality and reliable packaging machinery; you must also ensure that the technical support, training, and wear parts provided by the manufacturer are of the same caliber.
Technical support plays a vital role in the long-term success of your operation. If when unexpected problems occur, you need a support team that is knowledgeable, accessible, and responsive. It's frustrating and costly to be left waiting for hours or days to get assistance. Your support team should be readily available to provide guidance and resolve any issues efficiently. They should feel like an extension of your own team, dedicated to your success.
In addition to technical support, training is another important aspect to consider. Investing in high-quality packaging machinery means that you want to maximize its potential and ensure that your operators are fully equipped to operate and maintain the equipment effectively. Look for manufacturers that provide comprehensive training programs to ensure that your operators have the necessary skills and knowledge to optimize machine performance.
Wear parts are also a critical consideration when evaluating packaging machinery. High-quality and durable wear parts are essential to minimize downtime and maintenance costs. You want to avoid constantly replacing worn-out parts or dealing with frequent breakdowns. A reputable manufacturer will offer reliable and long-lasting wear parts, ensuring that your machinery operates smoothly and consistently.
Furthermore, it's essential that your support team understands the urgency and cost implications of machinery issues. Emergencies can arise at any time, and you need a support team that prioritizes your needs. They should be responsive and efficient in addressing any problems, minimizing the impact on your production and profitability.
Diving Deeper: Evaluating Your Machinery Solution
If you're currently deep in the weeds of evaluating a solution for your products and need a tool to help break down additional specifics, I recommend downloading our free comparison matrix spreadsheet. It's a good starting point for evaluating different vendors and machine specs and can help you understand where ROVEMA falls on the spectrum for many critical factors.
- Friday, November 3,
Are you interested in purchasing a capsule making machine? Have you ever wondered what kind of capsule filling machine would be perfect for your production? Are there questions about a capsule filling machine you have not been able to find suitable answers to?
Check out these primary questions you need to be answered before you order a capsule filling machine.
1. What are the basic things I need to know about a capsule filling machine?
A capsule filling machine is also known as an Encapsulating machine or Capsule filler. The capsule filler is used to fill the empty capsules with the required material, which could be solid, liquid, or semi-solid/liquid.
It is a popular device widely used in many industries, including the pharmaceutics, food, chemical, and packaging industry, and many other sectors. With the continuous advancement in technology, the latest capsule filling machine produces 200,000 capsules per hour with efficient automatic controls, including filling, positioning, locking, and counting.
2. What kind of materials do I require for a capsule filling machine?
There are two categories of capsules: soft capsules and hard gelatin capsules.
The soft capsules are filled with a blend of active ingredients in liquid or semi-liquid form. The soft capsule shell is usually made of gelatin, water, a plasticizer, and an opacifier, which could be glycerin or sorbitol.
Hard gelatin capsules are filled with single or combined forms of dry powder, granules, micro tables, small capsules, and coated beads. The shell consists of gelatin. Other substances, such as opacifiers, preservatives, colorants, and plasticizers are added to the hard gelatin shell to enhance capsule formation and performance.
HPMC capsules also known as hydroxypropyl methylcellulose capsules are also recommended due to their low moisture content compared to hard gelatin capsules. During the production/ encapsulation process, there could be brittle and breakage of the hard gelatin capsules under mechanical stress, which mainly happens due to the hygroscopic content of the hard gelatin capsules usually about 13% to 16%.
Read More:
What Capsule Dosage Forms Can be Used in Capsule Fillers?
3. What production capacity do I require for a capsule filling machine?
There are three major types of capsule filling machines which are:
- Automatic capsule filling machine
- Semi-automatic capsule filling machine
- Manual capsule filling machine
Depending on your production capacity, any of the three capsule filling machines would fit comfortably into your needs. It is also important to note that each type of capsule filling machine has its peculiar pros and cons.
Automatic capsule filling machine
The automatic capsule filling machine is preferred for large-scale production. Its operations are completely automated, and the device is durable and designed for long-lasting operations.
The production capacity of an automatic capsule filling machine is an average of 200,000 to 400,000 capsules per hour. It is frequently used in pharmaceutical companies with multiple-line productions.
Some of the benefits of the automatic capsule filling machine include:
- It has a high production capacity
- It has enhanced accuracy in filling capsules
- It is user-friendly
- It requires low maintenance
- There is minimal downtime during productio
Semi-automatic capsule filling machine
The semi-automatic capsule filling machine combines automated and manual operations. It is preferred for operations with varying sizes of powders, pellets, or granules. The semi-automatic capsule filling machine also has a high production capacity from 25,000 to 47,000 capsules per hour, subject to the operator&#;s skill set and capsule size.
Some of the benefits of the semi-automatic capsule filling machine include
- It has enhanced accuracy in filling capsules due to its automated operations.
- It is power saving
- It performs a quick and safe operation of filling and ejecting
- It is easy to upgrade
- It is easy to operate
Manual capsule filling machine
The manual capsule filling machine is completely operated by manpower. It is used in small to medium-sized productions. The device can open and fill about 300 capsules per cycle.
The parts of the basic model of the manual capsule filling machine can be changed and modified to fit your requirements.
Some of the benefits of the manual capsule filling machine include
- It is easy to operate.
- It has a simple design.
- It is cost-effective
- It has a precise filling, and it reduces powder wastage.
Also, before purchasing the capsule filling machine, it is advisable to consult with your vendor to make an efficient choice for your production capsule.
4. How do I determine my capsule size?
There are charts and graphs for the basic sizes and measurements of capsules and the required formulations and dosing units.
Capsule sizes usually range from sizes 000 to 5. The preferred sizes are 00 to 2 because they are easy to swallow.
EMPTY CAPSULE SIZE
Capsule Size
0
00E
0
0E
0
1
2
3
4
5
EMPTY CAPSULE WEIGHT
Average Weight (mg)
158
143
123
107
99
78
61
48
38
28
Tolerance
±10
±10
±7
±7
±6
±5
±4
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±3
±3
±2
EMPTY CAPSULE VOLUME CAPACITY (ml)
Capacity
1.37
1
0.9
0.78
0.68
0.48
0.36
0.27
0.2
0.13
FORMULATION DENSITY
Formulation Density
0.6g/ml
822
600
540
468
408
288
216
162
120
78
0.8g/ml
800
720
624
544
384
288
216
160
104
1.0g/ml
900
780
680
480
360
270
200
130
1.2g/ml
936
816
576
432
324
240
156
You can consult with your vendor to recommend the capsule size and capsule filling machine to fit your production needs.
5. How can I maintain a budget when purchasing a capsule filling machine?
Maintaining a production budget with top-quality materials can be very tasking. Also considering a fast line production and still staying ahead of the competition. Before maintaining a budget, it is essential to maintain top-quality production at all times.
While discussing with your vendor, he/she might suggest a capsule filling machine that is a little above your budget. You could revise your budget to get the right capsule filling machine needed for your production.
6. What is the maintenance routine for a capsule filling machine?
Every machine requires regular maintenance to guarantee its durability.
A regular maintenance routine involves
- Cleaning the machine with a nylon brush.
- Cleaning of the parts that come in contact with powders and materials after a period of production.
- There would be a need for a change of parts in cases of wear and tear.
- Wiping off the grease lines in the machine after a day of work.
- Regular opening and cleaning of the filter of the vacuum system.
- Periodic lubrication to ensure the efficient running of the machine.
Things you should avoid when cleaning the capsule filling machine are
- Do not clean the capsule filling machine with hot water or dip it in corrosive liquids (acids, alcohol, alkaline) overnight.
- Do not clean the machine with heating appliances, like an oven.
You can extend the shelf life of the capsule filling machine by 60 to 90% with proper cleaning and regular lubrication. It is advised to always clean the machine at the end of the day&#;s production. Do not leave powders in the machine overnight. It could dry and garden resulting in swift wear and tear of the machine.
7. What are the primary factors in choosing a capsule filling machine?
Now, there are some tips you need to consider before making the final choice for the capsule filling machine for your production. Let us look at them briefly.
- The reason for your purchase
The reason for your purchase of a capsule filling machine is very crucial. You need to consider the type of production you are after which could be
1. Hard gelatin or soft gel capsules.
2. Automatic, semi-automatic, or manual capsule filling machine.
3. Size of the capsule.
You need to consider the size of the machine you need for production. You can purchase a lighter machine for easy transportation between sites. Or you could get a larger capsule filling machine for better functionality if the production site is fixed.
Automatic capsule filling machines are recommended for large-scale productions with multiple lines. For small-scale production, a manual capsule filling machine is better to help save costs.
If you want to limit human contact and contamination of the product, it is better to opt for the automatic capsule filling machine.
Also, you could consider the customization option of the machine. There are available capsule filling machines that you can modify to fit your requirements.
As a manufacturer, you have an overview of the cost of the entire production. When making consultations about the type of machine to purchase, you should look out for a machine that is within your budget range without comprising the efficiency and quality of your products.
Conclusion
With all this information at your fingertips, the next step is to find a vendor that will guide you in picking the best capsule filling machine for your production
With 17 years of expertise, iPharMachine takes its place as one of the leaders in the pharmaceutical and pharmaceutical packaging industry. We prioritize quality equipment over quantity and are dedicated to providing the best capsule filling machine and other pharmaceutical machines you need in your production.
Following years of production of capsules and related equipment, we have patented several capsule-related technologies. The team at iPharMachine focuses on research and development and provides pharmaceutical engineering solutions that meet cGMP standards.
We also offer consultations to help guide you in picking a suitable capsule filling machine. iPharMachine provides all types of capsule filling machines (automatic, semi-automatic, and automatic), and also matching separated and joined capsules.
Order your capsule filling machine today at iPharMachine.
The company is the world’s best Manual Powder filling machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.