Knowing the types of capsule filling machine and their differences can help you make the right choice. That’s because production needs, such as output volumes, vary widely. Continue below to learn more about the filler types, including crucial selection factors.
How are Capsule Filling Machines Classified?
We mainly classify fillers by the type of capsules they fill, which can be hard or soft gelatin. We also group them by their automation grade, with options ranging from manual to autonomic.
The automatic types differ in filling mechanisms, giving rise to two versions. Other classification features include production capacity, capsule size, and construction materials.
The following section explains the different types of capsule-filling machine in detail. Use it to understand the available choices and what best suits your usage requirements.
Types of Capsule Filling Machine
Diverse types of capsule fillers exist on the market today. As such, buyers must carefully select them based on specific application requirements. They include the following, classed by their mechanisms and other features.
1. Manual Filler
The manual capsule filler relies on you to operate it. Depending on the version, it can be a simple device with loading trays. It can also be a lever-operated machine with more components and filling steps.
The machine is straightforward to use and inexpensive, with some costing around $100. However, it has low filling speeds and requires more labor. Its operation is also prone to errors and inaccuracies.
Manual/hand-operated capsule filler machines are best for low production or intermittent filling. They are best for personal and research uses, such as producing dietary supplements, lab tests, and educational demos.
2. Semi-Automatic Filler
The semi-automatic machine combines manual and self-operating production steps. In other words, the operator must perform some tasks. The tasks include capsule and material loading, cap separation, etc.
Faster than the manual type, the semi-automatic capsule filler increases speeds to several thousand pieces per hour. It also reduces labor requirements and is best for small to medium businesses.
3. Fully Automatic Filler
This type fills capsules without requiring operator intervention. The automation starts at capsule feeding and ends when it ejects them filled. Sometimes, the process goes beyond ejection to include capsule polishers, counters, etc.
The machine is the most complex of all fillers. It also has high speeds ranging from 10-100k pieces an hour. Furthermore, it offers high accuracy levels and consistency despite costing more.
You can integrate automatic machines into existing production lines or use them with auxiliary equipment like packaging systems. They suit large-scale production requirements, including those of giant companies.
4. Soft Gelatin Filler
The soft gel type is a specialized device that only works with soft gelatin. These are high-moisture gels for flaccid encapsulations. The capsules can be dietary or medicinal and other products.
The machine is also available in either semi or fully automatic types, suiting various usage needs and budgets. That, in turn, allows buyers to match their choices with application and budget limitations.
Soft gel fillers are complex equipment since they combine capsule production and filling. They also cost more but are necessary to produce soft encapsulations for your market.
5. Tamping Pin Filler
This type of capsule filler derives its name from the pins it uses to measure the fill material before sending it into the capsules. The mechanism comprises several projections and a dosing disc with holes drilled through it.
The projections descend into openings on the filling, compressing powders, granules, or material into plugs. On the other hand, the dosing disc thickness controls the plug size and, therefore, the fill material weight.
The tamping pin filler is an automated device with high speeds and precision. It comparably works faster than the dosator type. It also has a more straightforward design, costs less, and doesn’t produce much noise.
6. Dosator Filler
The dosator capsule filling machine works using tubes equipped with pistons. The tubes measure and compact the fill material. The resulting mass goes through a scraper for doctoring before entering the capsule body.
Like the tamping pin filler, machines that use dosator mechanisms are automatic systems for higher production runs. The mechanism has various benefits, such as higher precision and powder adaptability.
On the downside, the machine has a complex construction that makes it more expensive. It also produces more noise and is slower than the tamping pin type, making it less favorable for some uses.
Which Type of Capsule Filling Machine Should You Use?
It depends on several factors, such as business size, capsule or material type, and budget. With that in mind, let’s look at how you can select a suitable machine for your business or other use.
Assess Your Needs
Consider your needs per session, hour, or day. A fully automatic type is your best choice for higher volumes above 10,000 capsules per hour. Semi-automatic fillers are generally suitable for 10k pieces or less.
On the other hand, consider a manual device if the filling is occasional. You also need it if you fill less than 1k pieces per session. Given its fewer parts and manual operation, it costs less to purchase and use.
Capsule and Fill Material Type
Most machines fill hard gelatin capsules. For soft encapsulations, you need a soft gel machine. This device produces and fills the soft shells inline.
You must also ensure the machine can fill your product and capsule size. That said, most fillers can adapt to variations using interchangeable parts.
Budget Constraints
Some filler types are more expensive than others, including models in the same category. Make sure your choice fits your budget without affecting your usage needs.
For instance, semi-automatic fillers are more affordable than fully automatic types. You can choose these for most production needs, from low to high.
On the other hand, a fully automatic system is a worthy investment for demanding applications. These include the output requirements of companies in the beauty and pharmaceutical industries.
Commercial vs. Capsule Filling Machine for Home Use
The filler applications are either personal for small-scale needs or commercial and require elaborate machinery. Users buying fillers for either application must understand the best options for each.
A filling device for home use is usually a manual device that you operate with your hands. It has a modest filling speed, usually between 300 and 800 pieces per cycle.
Commercial capsule-filling machine types are extensive systems with many moving parts. They produce more pieces per minute (over 10k) and come with varying speeds to suit your business.
Conclusion
The types of capsule-filling machines today are as diverse as their applications. When selecting one, ensure you understand the benefits and drawbacks of each. You can expect your business to achieve greater efficiency and profitability with the right machine. That’s in addition to meeting your budget constraints during purchase.
