AUTOMATIC AND SEMI-AUTOMATIC CAPSULE FILLING MACHINES:
As discussed in the previous post, i.e. in Part - 1 of 2, the process of Hard Gelatin Capsule Filling essentially requires a series of actions viz:
a. Empty Capsules loading into the Loading Hopper
b. Rectification of the Capsules i.e. orientation of the capsules in such a way that body faces downwards (towards the ground) and cap faces upwards (towards the sky).
c. Separation of the Cap from the Body
d. Loading the powder (or active ingredients) feed material into its feeder
e. Slug formation of the feed material
f. Dosing the slug formed into the capsule
g. Placing the Cap back on the Body of the capsule, and thus locking them together.
h. Polishing and Sorting of the capsules (optional)
i. Ejection of the filled capsules from the system (incase of any automatic system)
AUTOMATIC VS SEMI-AUTOMATIC CAPSULE FILLING MACHINES:
The series of actions discussed above, if are arranged to take place in a synchronized manner, then the facilitating equipment is known as an Automatic Encapsulation Machine.
However, in a Semi Automatic machine, some of these activities require manual intervention. A Semi Automatic Machine is more closer to a Manual Capsule Filling machine than Automatic one. In the Semi Automatic one, the Capsule Rectification is automatic. Similarly, the slug formation and capsule feeding is automatic. Finally, after matching top and bottom plates, the action of sealing the body with cap is automatic. Overall, the efficiency is very low, as, almost 70% percent activities are to be performed manually.
On an average, the output of the Semi Automatic machine could be in the range of 15,000 to 25,000 capsules per hour, whereas, that of a Manual machine could be upto 15,000 capsules/ hr. The Fully Automatic Capsule Filling can have an output as high as 150,000 capsules/ hr Or may be even more.
AUTOMATIC CAPSULE FILLING MACHINE IN DETAILS:
1. Capsule Feeder and the Process of Rectification: The Feeder Hopper is loaded with the empty capsules manually. The capsules eventually fall into a vertical cage like structure and forms a vertical array, where, a back and forth reciprocating plate pushes them ensuring the capsules are oriented in one direction only ie. Cap upwards and Body downwards.
2. Separation of the Cap from the Body: The Rectified Capsules are further ejected into the upper part of the Turret. A low vacuum (generated by the vacuum pump) creates a pulling force, which resists and holds back the body part of the capsules, as those are engaged with the lower portion of the rotating Turret plate, which has a rotary indexing motion and thus keep transporting the capsules from one station to other station.
3. Powder Feeding and eventually Capsule Filling: The feed material Or powder is fed to the hopper (mostly manually Or with the help of some powder transfer mechanism). The feed material is further driven to the tamping assembly with the help of a screw type agitator Or auger. The temping assembly consist of serval sets of reciprocating tamping pins and dosing discs which are rotary indexed. These dosing discs has the small cavities where the powder sits and are compressed by the tamping pins progressively. The last set of the tamping assembly pushes the slug formed into the capsule body.
(Pic Ref: www dot jicon dot com)
4. Other forms of Ingredients Feeding into the Capsule Body: Apart from the powder, there can be other feeding material like Pellets Or Tablets etc. There are a few extra stations available on the main turret. The feeding mechanism is designed based on what to be fed, its nature, the size and diameter of the capsule body.
(Pic Ref: www dot jicon dot com)
5. Filled Capsules Ejection: The tamping pins pushes out the filled capsules towards the end of the rotation.
6. Filled Capsules Sorting, Polishing and Dust Collector: Separate attachments are provided each of the functions like capsule sorting, capsule polishing and dust collector.
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