Fully Automatic Capsule Production Line

Precision Engineering for Pharmaceutical Excellence

Our Fully Automatic Capsule Production Line represents the pinnacle of modern pharmaceutical manufacturing technology. Designed to optimize efficiency, ensure product consistency, and adhere to global regulatory standards (e.g., GMP, FDA, EU), this integrated system streamlines capsule production from raw material processing to finished packaging. Each stage is equipped with cutting-edge automation, real-time quality monitoring, and adaptive controls to meet diverse formulation requirements.

Production Workflow & Technical Specifications

Pulverization (Crushing)

    Process: Raw materials (APIs, excipients) are fed into high-speed micronizers or impact mills to achieve ultrafine particle sizes (typically 10-100 microns).

    Technology: Utilizes airflow pulverization or cryogenic grinding for heat-sensitive compounds to prevent degradation.

    Output: Uniform powder with enhanced dissolution properties for optimal bioavailability.

Sieving (Screening)

    Equipment: Vibratory or rotary sieves with stainless-steel mesh screens (mesh sizes customizable from 20 to 200目).

    Function: Removes oversized particles, aggregates, and foreign matter. Equipped with ultrasonic deblinding to prevent mesh clogging.

    Quality Control: In-line particle size analyzers ensure compliance with predefined specifications.

Mixing & Granulating

    Mixing: High-shear mixers or twin-screw blenders homogenize APIs and excipients. Loss-in-weight (LIW) feeders ensure precise ingredient ratios.

    Granulation: Wet granulation (using binders) or dry granulation (roller compaction) transforms powders into free-flowing granules. Fluidized-bed granulators enable continuous processing with controlled humidity and temperature.

    Key Benefit: Improved flowability and compressibility for accurate dosing during capsule filling.

Drying

    Technology: Fluidized-bed dryers or vacuum drying ovens remove moisture to <2% (varies by formulation).

    Control: Real-time moisture sensors (NIR or capacitance-based) adjust drying parameters dynamically.

    Output: Stable granules resistant to caking or microbial growth.

Regulation (Sizing/Milling)

    Process: Granules pass through oscillating granulators or cone mills to break agglomerates and achieve uniform particle size distribution.

    Precision: Adjustable rotor speeds and screen apertures ensure granules meet strict size specifications (e.g., 0.5-2.0 mm).

Final Blending

    Equipment: V-blenders or bin blenders with intensifier bars for homogeneous mixing.

    Quality Assurance: Near-infrared (NIR) spectroscopy or Raman probes monitor blend uniformity in real time, ensuring RSD <5%.

Capsule Filling

    Machines: Servo-driven capsule fillers with multi-dose turrets (e.g., 8-12 stations) for high-speed filling (up to 200,000 capsules/hour).

    Dosing Technology:

        Dosator Pumps: Ideal for free-flowing granules.

        Tamping Pins: Suitable for cohesive powders.

        Accuracy: Weight variation controlled to ≤±3% (meets USP <795> standards).

        Capsule Types: Compatible with gelatin, HPMC, or vegetarian capsules (sizes 000 to 5).

Polishing

    Process: Capsules pass through rotating polishing drums with food-grade cloth brushes to remove excess powder and ensure smooth surfaces.

    Dust Extraction: Integrated HEPA filters eliminate airborne particles, maintaining cleanroom compliance (ISO Class 5-7).

Packaging

    Options:

        Blister Packaging: High-speed thermoforming machines with aluminum/PVC films.

        Bottle Filling: Automatic counters with desiccant insertion and induction sealing.

        Bulk Packaging: Flow wrappers or pouching systems for clinical trial batches.

        Traceability: Barcode labeling, laser printing, or RFID tagging for serialization (meets DSCSA, EU FMD requirements).

System Highlights

    End-to-End Automation:

        PLC & HMI Controls: Centralized touchscreen interface for recipe management, parameter adjustment, and error diagnostics.

        CIP/SIP Systems: Clean-in-Place and Sterilize-in-Place capabilities reduce downtime between batches.

    Quality by Design (QbD):

        In-process checks (IPC) for weight, hardness, and disintegration.

        Data logging with 21 CFR Part 11-compliant software for full audit trails.

    Flexibility:

        Quick-changeover design supports R&D, pilot-scale, and commercial production.

        Modular architecture allows integration with third-party systems (e.g., vision inspection, metal detectors).

    Sustainability:

        Energy-efficient motors and heat recovery systems reduce carbon footprint.

        Material waste minimized via closed-loop recycling of overfills.

Applications

    Ideal for producing:

        Nutraceuticals: Multivitamins, probiotics, herbal extracts.

        Pharmaceuticals: Antibiotics, NSAIDs, controlled-release formulations.

        Veterinary Products: Pet supplements, medicated capsules.

Why Choose Our Production Line?

    Turnkey Solutions: Customized layouts, installation, and validation support. 

    Global Compliance: Designed to meet FDA, EMA, WHO, and ICH guidelines.

    After-Sales Service: 24/7 technical support, spare parts availability, and operator training programs.

Elevate your capsule manufacturing with a system engineered for precision, scalability, and regulatory confidence. [Contact us] today to request a demo or tailored quotation!