Technical parameters of an auto capsule filling machine are multi-dimensional technical parameters and performance measures with direct impacts on the efficiency of pharmaceutical production and product quality. Using a popular model as a reference, its speed for filling capsules can be 300 to 800 capsules per minute, the error rate is less than 0.5%, suitable for capsule sizes ranging from 000 to 4, the filling range can be precisely controlled within 0.1 ml to 1.5 ml, and the dose fluctuation control is achieved through servo motor drive system of ±0.5%. The power configuration of the equipment is generally 2.2 kW to 5.5 kW, and the working pressure of the air compressor should be maintained at a stable level of more than 0.6 mpa. The replacement time is shortened to 30 minutes with the modular configuration, significantly improving the utilization rate of the equipment. Germany’s Bosch Group in 2022 launched GKF 2700 series machines, with 98.5% pass rate in closing the capsule, and reduced the loss rate of the drug from 3.2%, which was the industry rate, to 1.8%, conserving raw material cost of around $120,000 every year for mid-sized drug companies.
In environmental flexibility, the auto capsule filling machine must meet GMP clean shop standards and be equipped with a HEPA filter in order to provide clean air to ISO Level 5 standards and less than 1 microgram/cubic meter of dust leakage. MG2, a Swiss company, solves the stability problem of tide sensitive drugs through its NT series products by maintaining the filling area at 20±2℃ and humidity fluctuation at 45%±5%RH through a temperature control module. The material of the equipment is 316L stainless steel, the surface roughness Ra≤0.4 microns, and the completely enclosed structure design, so that the cleaning verification cycle is extended to 72 hours, and the continuous operation ability is improved by 40% compared with the traditional model.
The intelligence level has a direct effect on the return on investment of the equipment. Capsugel’s Quali-V series vision system uses a 2-megapixel CCD camera to detect capsule defects at 50 frames per second and employs deep learning algorithms to control the false detection rate at 0.3%. With the support of OPC UA protocol, the equipment can be communicated with MES system smoothly and acquire 35 kinds of process parameters in real time, and the batch recording time is saved from 4 hours to 15 minutes. In 2023, the 20 automatic capsule filling machines released by Pfizer’s China factory optimized the load difference from ±7% to ±3% through the application of dynamic weighing compensation technology, the product pass rate reached 99.2%, and the annual production capacity exceeded 4.5 billion capsules.
Cost benefit analysis shows that the average auto capsule filling machine ranges from $180,000 to $350,000 in cost of purchase, and the maintenance costs are 8-12% of the original investment per annum. The new servo direct drive technology machine, however, conserves 22% of energy as opposed to the traditional model, at $0.12 / KWH, a yearly electricity conservation of $4,500. For Indian pharmaceutical company Sun Pharma, the OEE of the capsule filling line was improved from 68% to 84% through equipment upgrades, the payback time was reduced to 26 months, and the modular design extended the equipment life to 12-15 years. Existing market trends indicate that models with in-line cleaning (CIP) and in-line sterilization (SIP) functionality, while 25-30% more costly, can minimize product switching time by 60%, generating higher value in flexible manufacturing.