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CAPSULE BASE PREPARATION

Melter (Cooking Vessel) is a piece of essential encapsulation equipment, High performance completely independent for capsule base preparation.

GELATIN MELTER

​All the operation of the machine is made from the frontal HMI.

The panel controls all the functions of the system, including:
a) Motor control, b) Heating and cooling system, c) Auxiliary functions

 

Melter 1000 is a machine used for gelatin preparation. It is provided with a slow anchor agitator and a fast rotation impeller used to mix instantaneously the charged raw materials. The raw materials are charged by using a powerful vacuum pump.

 

Once the liquids are inside the vessel at the right temperature, the gelatin powder is sucked and the high-speed impeller dissolves it immediately creating a perfect mixing mass. The heating is provided by the water that circulates inside a jacketed vessel. During the De-aeration phase, a level sensor ensures that the gelatin foam doesn’t arrive at the vacuum pipe. Electronic weight cells keep under control the weight of the mass inside the vessel to ensure the maximum precision of the procedure. Once gelatin mass is ready, it is discharged by pressure through the discharge valve.
 

At the end of the process, a cleaning in place procedure can be executed to leave the equipment perfectly clean, and ready for the next batch.

FILL PREPARATION
EQUI

For fill (Medicine) preparation. Unit with contra-rotating agitator, mobile scrapers, and bottom entry fast agitator in the conical vessel

Its mixing system consists of three agitators:

  • an anchor-type outer agitator enabling a bottom-up recirculation

  • a blade-type inner agitator enabling a top-down recirculation

  • a bottom-mounted homogenizer enhancing the shearing and mixing effect as well as giving stability to the emulsion

Slow Contra-Rotating Agitator

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Fill preparation Unit with contra-rotating agitator, mobile scrapers, and bottom entry fast agitator with heating, cooling, and vacuum services. Useful for a minimum of 150 lit to 500 lit.

Vessel: cylindrical vertical, with upper flange with slow agitation group with two inverters for step-less speed variation and truncated-cone bottom with high-speed homogenizer stirrer controlled from the control board.The anchor-type agitator is equipped with Teflon scrapers whose function is to transfer the product from the inner surface of the mixer towards the inside in a way that accelerates the mass heating or cooling that occurs through the heating-cooling circuit placed in the mixer’s jacket.

High-speed agitator, installed on the mixer bottom, with one inverter forstep-less speed variation controlled from the control board, equipped with disperse - homogenizer turbine head, rotor/stater assembly.

Product mixing is further enhanced throughout an external recirculation, with two inlet points (lower and upper), with the pumping effect directly from the homogenizer

The Mixing unit is equipped with an internal CIP system engineered according to GMP standards.

A - ENCAPSULATion machine LINE WITH TRAY DRYING

Encapsulating Machine with Electrical Control Panel, Capsule Conveyor, And Tumbler Dryer 6 Baskets, And Drying Tunnels.

 

 

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ENCAP MACHINE - TRY-DRYER
ENCAPSULATION PROCESS

 High speed encapsulating machine is a piece of modern encapsulation equipment, suited for middle to high-scale production. All the operation of the machine is made from the frontal HMI. The panel controls all the functions of the system, including a) Motion control; b) Heating and cooling system; c) Auxiliary functions (ex. Gelatin feeding, lubrication oil for gelatin, and others); d) Tumble dryer system. The machine is equipped with a state-of-the-art technology motion system. The main component of the machine are driven by independent motors, this allows accurate and precise handling of the gelatin ribbon and a highly accurate filling of the capsule. The Die Roll assembling in the Die Roll Coupling Housing assures the total safety of the Die Rolls during rotation. The electronic failure of the Servo motors cannot damage the Die Rolls.No physical connections between the capsule formation area (Clean Area) and rear technical area. The Die Roll cleaning operations can be performed automatically out of the machine, before removing the Die Rolls. The change over time is extremely reduced. The medicine pump is synchronised with the die roll through an electrical cam, controlling the exact injection timing.
 

B - ENCAPSULATion machine LINE WITH IN-LINE DRYING

High Speed Encapsulating Machine with Electrical Control Panel, Capsule Conveyor, And Double Deck Twin Tumble Dryer For Drying in Line (Continues Drying)

 

 

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ENCP MACHINE - TUMBLE DRYER

​                                        Key Features

  • Die-Roll coupling housing assembly is detachable. - Easy for maintenance job

  • Medicine Pump Slides Lubrication System with the micro oil filter is made by a separate pump with an electronically controlled oil flow regulator.- Pump life increases substantially.

  • Ribbon formation is electronically controlled. Uniform ribbon thickness maintain.

  • Electronically control Die-Roll pressure regulates pressure as small as 1% incremental.- Die-Roll life increases substantially.

  • Automatic synchronization of the Medicine pump injection with the Die Roll pockets. No setting is required for injection timing.- No medicine net loss.

  • SS 316L Spreader-Box with gelatin level sensor.-Uniform level of gelatin in the spreader box ensure uniform ribbon thickness throughout the batch.

  • HMI Panel including Checkup of the machine, Encapsulation line operations, Capsules counting, Production hours counting, Production data record for each working shift, Data printing possibility, Recipe storage. - GMP compliance.

  • Modular 6 baskets tumble dryer with controlled speed and air draft; High drying efficiency, Easy cleaning,  Easy and fast production changeover. The basket unit is mounted on a mobile wheel for easy removal from the drying system for the washing process. 

  • Advance Key Features:

    • Air pressurised gel feeding system; sonar gelatin level in gel tank, spreader box reflective sensor, ss 316L gelatin pipeline set with electric heater - CIP enabled. 

    • Air pressurized fill feeding system; sonar fill level in fill tank. pipelines set for medicine feeding.

IN-PROCESS QUALITY CONTROL

In-Process Quality Control (IPQC) of Pharmaceutical Dosage Forms. The function of in-process quality control is monitoring and if necessary adaptation of the manufacturing processes to ensure that the product conforms to its specifications.

CAPSULE HARDNESS TEST

Advancement in the softgel hardness testing

Testing device digi test ll

Reading in the display gives the correct idea of capsule  (highly elastic materials) hardness, suitable to final packaging. 
 

CAMERA LEICA

Useful for checking the capsule shell thickness and capsules seam.

During the encapsulation. 

Verifying perfect die roll alignment during the machine setting 

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WEIGHT VARIATION

The capsule's weight is routinely measured to help ensure that  the capsule contains the correct amount of drug/fill.  

post ENCAPSULATION

CAPSULE sorting & polishing

Size Graders to automatically and continuously remove over and under-sized product and Continuous Polisher to remove mineral oil and residual capsule filling

from product

capsule inspection

Capsule inspection is an important process.During the process it

Verify capsule quality – detect, remove and record foreigners and defects such as D-shaped, bulges, stains, air bubbles and broken or malformed capsules.

remove small, leaker, misshaped, subtle colour, or foreign capsule.  

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