A series of softgel encapsulation machine models are available for options. Range from lab size, medium size to mass production scale. JS-4: 20K capsules per hour based on 500mg Oval fish oil soft gelatin; Best choice for small-scale production. JS-6 and JS-7 model: Output per hour: 40k-45k per hour, are good for middle scale softgel production. JS-8 and JS-10: Yield per hour: 80K-100K fish oil softgel of 8# Oval for mass production factories.
Chinese Softgel Encapsulation Machine Characteristics JS series softgel capsule machine runs stably for a continuous 24hours, 7days per week, all year round with very stable working conditions.
Plunger precisely filling into mold cavities, accurate soft gelatin weight. Three types of plungers for options such as100-250mg, 250-1000mg, and＞1000mg. For pharmaceutical softgel it is very important to control a small and precise filling accuracy. Users can either choose to have a set of a standard 0-2ml plunger for all products or change the plunger to suit different filling dosage capsules.
V-type polytetrafluoroethylene(PTFE) sealing ring inside the injection pump, more accurate than the regular O-type seal.
Automatic Gelatin ribbon thickness adjustment is an option.
Gelatin ribbon width is also adjustable to fully cover the die roll surface.
Imported Japan brand medicine filling pump is used to transfer material, precise and sanitary.
Touch screen and PLC make all settings and operations easier.
The whole Machine is made of an aluminum frame with 304 covers, the contact part material is 316L.
Lubrication System: Micro lubrication, reduce the conventional too oily situation. Reducing paraffin oil consumption and saving costs.
Dies Symmetry: Parallelism≤0.02mm; reduces operation failure.
Ultra-High accuracy temperature control;
Extremely low gelatin wastage;
Ultra-high precision cooling drum: water cooling instead of conventional machine fan cooling.
Independent capsule stripper has driven: gelatin ribbon peels off easily.
Independent mangle roller drove: easier adjustment and fine-tuning.
Automatic hopper level control: easy checking the filling material inside. With capsule accumulation counter.
First of all, it’s better to know more about the working principle of softgel machine before telling the difference. I’d like to call it a cold press and cutting process where two sheets gelatin ribbons be cut under the cold press of two parallel die rolls. Meanwhile plungers inject the shaped gelatin ribbon shell with measured amount of liquid.
Let’s take a look at the Video about softgel encapsulation machine for a quick understanding.
Shared by youtuber ‘Catalent Pharma Solutions’
What are Softgel Encapsulation Machine Major Components?
Softgel machine is a complicated device combines many parts and components, here briefly introduce the most basic and crucial parts which matters during encapsulating.
Die rolls: a vital and precise part that relates softgel shape, size and seam. It influences the finished softgel capsule appearance and quality.
Filling pumps and plungers: softgel is a small dosage which requires a high filling accurate filling devices. The pump and plunger’s precision decides the softgel filling weight. A quality controlling issue for QAs.
Cooling Drum (Gelatin Ribbon Drum): the gelatin solution flows onto the cooling drum to become sheets of gelatin ribbon. It should be clean and maintain a stable temperature during encapsulation. For paste softgel, the cooling drum should have a relatively higher temperature so that softgel can have a strong seam. The cooling system runs through the encapsulation machine to cool down parts that need to be low temperature.
Gel box: two brass containers on the softgel machine to hold gelatin solution; it has heater to keep a temperature to ensure a good fluidity gelatin solution; a liquid level detector to ensure the quantity of gelatin and to avoid overflow. This part needs well installed onto the cooling drum, otherwise the gelatin ribbon thickness will be affected.
Medicine Hopper: installed on top of the encapsulator; generally, the hopper built with a hot water jacket to provide heat preservation function, stirrer (can mix the liquid a little bit when needs); liquid level detector. At least 5 kilograms of filling material is recommended to load into the hopper; too little material might cause the machine to plunge emptily.
Operation panel: touch screens and PLC systems is preferred by most users. Combining parameter settings into programmed Logic Controller to make operation easier, especially with servo softgel machines.
Conveyor: transfer the soft capsules into tumbler dryer, bi-directional.
How many shapes and size of softgel capsule can make?
Soft gelatin capsules have many shapes and sizes; One softgel machine is capable of encapsulating all those by change rotary rolling dies. Most common shape is Oval 8# and Oblong 20#; now small batch of special shapes of softgel become more and more popular such as animal shapes for kids, flower, star, Saturn shape for cosmetics and big dosage suppository shape for animals.
Shapes and sizes are open for customization, not limited.
How to calculate capacity and choose a suitable machine?
The first thing to decide is the softgel manufacturing yield. Users should be clear of how big production need is. For example, a 100K caps per hour softgel machine, when it runs at full speed for 8hours, the outcome is 800K softgel. For different users, production shifts and time differ like 7/24 working mode; or 10hours/day/shift working.
Considering the loss and production rate during actual production, the buyer better chooses a softgel machine with a capacity of 10-15% higher.
Secondly is the auxiliary equipment such melting tanks, tumbler dryers, drying trays. The same softgel encapsulation machine, runs 16hrs consumes twice gelatin and medicine than 8hrs operation. Therefore, the size of the gelatin melting tank and medicine preparation tank should enlarge accordingly; the quantity or size of tumbler dryers increases.
From the 2 points we can see that a softgel manufacturing line price varies due to auxiliary equipment configuration. It’s a must to discussion need with suppliers before quotation. The comparison should be based on the same requirement.
What is the cost for softgel manufacturing equipment?
The cost of a softgel manufacturing line differs much according to the various capacities and configurations. There is no quick answer to this question. However, a line about 100K capsules per hour price around 110,000~150,000USD, changing with auxiliary equipment URS.
What else should also be aware of?
When you plan a plant, besides machinery, other facts should be taken into consideration too.
Cleanroom space and non-cleanroom space for all those softgel manufacturing equipment, including entry, installation and maintenance size. Corridors and doors size to pass through is mostly neglected.
Machinery wiring and piping. This is a part that usually be neglected. The purchasing department is in charge of buying softgel manufacturing equipment, but they usually know little about what they are sourcing. So a professional and experienced supplier should inform buyers about this. To use a softgel line, you need clean water, hot water, vacuum, compressed air and power.