Semi Automatic Encapsulation Machine: The Complete Buying Guide In 2024

1.What Is A Semi Automatic Encapsulation Machine?

AIPAK- CGN-208S Double Head Semi-Automatic Capsule Filling Machine

Semi automatic encapsulation machine refers to the compact machine designed to fill hard gel capsules with substances such as powder, granules, and pellets etc. It can efficiently produce about 20k capsules in an hour, thus, play significant role in drug manufacturing.

The machine has simple structure with convenient working process which is based on semi-automatic technology where a single operator is required to intervene for carrying out the operation. It precisely weigh the material and safely fill it into capsules followed by simultaneous sealing. Hence, it is best suitable for medium scale pharmaceutical, nutraceutical, and veterinary industries.

2.Explain The Features Of A Semi Automatic Encapsulation Machine?

Semi automatic encapsulation machine offers certain benefits which are associated with its features. These are explained below:

Cost-effectiveness

Cost-effectiveness image- Picture Courtesy: Shutterstock

The foremost attribute of a semi automatic encapsulation machine is its cost effectivity in a way that its price is affordable than fully automatic machine way. Similarly, unlike manual machine, it can work automatically by just the involvement of a single operator. Ultimately, it reduces the overall cost of capital and labours.

Simplicity

User pressing emergency stop- Picture Courtesy: capsugel.com

The machine has simple design and operational procedure which is easy to understand and practically execute. No additional tools are required for attaching, thus, little barriers are caused during operation.

Compact Structure

Compact structure- Picture Courtesy: capsugel.com

It has small structure with precise footprint that covers less space and easy to locate anywhere. Its body is made from quality stainless steel which is fully safe against bacteria and corrosion.

Efficiency

High efficiency of semi automatic encapsulation machine- Picture Courtesy: capsugel.com

Although, semi automatic encapsulation machine works on semi automatic principles basis, it has still high production efficiency by filling about 10k to 12k of capsules. Therefore, it is best compatible to meet the needs of medium scale production line.

High Accuracy

The most significant feature of the machine is its high level accuracy in terms of measuring exact amount of material till its filling into capsules. In this way, it maintain consistency in finishing encapsulation task.

3.What Type Of Material Can Be Filled By A Semi Automatic Encapsulation Machine?

Well, a semi automatic encapsulation machine can deal with various material for their filing into capsules. These vary from free flowing powders to granules and pellets. Details are as follows:

Powders

Powder released from capsule- Picture Courtesy: syntegon.com

Powders are the most commonly found material inside hard gel capsules as get dissolve quickly. For this reason, you can simply load the semi automatic encapsulation machine with bulk of powder and it will fill precise dosage in each capsule.

Granules

Granules falling from opened capsule- Picture Courtesy: Freepik

In addition to powder, granules are often filled in capsules as drugs. These granules are made through wet granulation or dry granulation to properly mix the solvent or binder solution with APIs.

Pellets

Pellets- Picture Courtesy: nuts.com

Small pellets can also be filled by this machine into capsules. These pellets are useful for capsule dosage which are meant for modified or extended release as the pellets will take longer time than powder to dissolve in body.

Tablets

Capsule with tablets- Picture Courtesy: syntegon.com

You may wonder how tablets can be filled into capsules but that's true. Small size tablets can be delivered in form of capsules to mask their unpalatable taste or slow down the dissolution timing. Similarly, it also enhances the convenience in swallowing.

4.Are There Any Recommended Capsule Size You Can Use With A Semi Automatic Encapsulation Machine?

Various sizes of capsules- Picture Courtesy: huadapharma.com

As far as the recommended capsule sizes for semi automatic encapsulation machine is concerned, so, the answer is yes! There are various sizes of hard gelatin capsules which you can process with this machine. These sizes start from 00 and include 0, 1, 2, 3, 4, and 5 sizes of capsules with powder, pellets, and granules.

5.Which Type Of Capsules Can You Fill Using A Semi Automatic Encapsulation Machine?

Well, a semi automatic encapsulation machine is capable of filling any kind of hard gel capsules with different materials. In this way, the common capsule types include:

Gelatin Capsules

Various gelatin capsules- Picture Courtesy: mankindpharma.com

Gelatin capsules refer to the hard gel capsules which are made from animal sources by boiling their bones and skin etc. These capsules have a primary ingredient known as collagen which is translucent and tasteless making it easier to swallow. Thus, you can fill gelatin capsules of different sizes and colors by using a semi automatic encapsulation machine.

Vegetarian Capsules

Vegetarian capsules presentation idea- Picture Courtesy:Freepik

As the name indicates, vegetarian capsules are derived from plant sources which lacks collagen. These capsules are stable as having low amount of moisture. Vegetarian capsules can be further divided into HPMC or Hydroxypropyl methylcellulose capsules and pullulan capsules. These capsules are also eligible to be filled by a semi automatic encapsulation machine.

6.What Are The Working Principles Of A Semi Automatic Encapsulation Machine?

As far as the working principles of a semi automatic encapsulation machine is concerned, so, it follows a very gentle procedure where the machine work along with little inference of the operator. Let's, look into these steps for more clear understanding!

Machine Loading

Operator loading machine hopper- Picture Courtesy: capsugel.com

The process gets start with machine loading. It includes the loading of empty capsules into the capsule shell silo, while as, feeding the hopper with filling material which can be powder, granules, or pellets.

Machine Setting

Operator setting machine through HMI- Picture Courtesy: capsugel.com

Now, another step is to properly set the machine by carrying out fixation of its parameters such a as the amount of material to be filled in each capsule, the vibration of powder hopper, or regulating the speed etc.

Capsule Orientation

Capsule orientation into filling ring- Picture Courtesy: fve.international

Once the machine setting gets done, it is ready to be started. As soon as the machine is powered on, the capsule silo start shaking which cause capsules to fall into seeding agency. Similarly, these capsules are then pushed by the seeding into into a rotating capsule station. The body part of capsules are ejected into the lower station followed by capsules cap in the upper station.

Capsule Filling

Capsule filling- Picture Courtesy: capsugel.com

Now, the capsules filled plate is taken out by the operator. The plate holding capsule lower shell is placed under the material feeding unit. Here, the accurate dosage of material is discharged into capsules and the excess material is removed.

Capsule Locking

Capsule locking- Picture Courtesy: capsugel.com

Moving forward, the plate carrying filled capsules is again manually removed by the operator. At this point, the dual stations of capsules holding upper and lower parts are placed in locking plate. Upon applying pressure, the separate capsule shells, body and cap, meet and capsules are locked against material leakage.

Capsule Discharging

Capsules discharging- Picture Courtesy: capsugel.com

Finally, the finished capsules are ejected put of the plates into a collection container.

7.Describe The Major Components Of A Semi Automatic Encapsulation Machine?

Semi automatic encapsulation machine is composed of several components which are described below:

Components of AIPAK- CGN-208S Double Head Semi-Automatic Capsule Filling Machine

Hopper

It is also called powder hopper which is used to hold the fill material. The hopper comes in auger form allowing easier flow of powder during operation. It also has a inlet from where user can refill it easily.

Capsule Shell Silo

It refers to the capsule hopper where bulk empty capsules are loaded before operation. The number of capsule shell silo vary according to Machine design such as single head or double head semi automatic encapsulation machine etc.

PLC Control Panel

As the machine features automation, it is simply represented by the PLC control panel which is equipped with human machine interface. User can easily interact with it, set commands, and control the performance of machine through it.

Capsule Sealing Section

Capsule sealing section is another significant part of the machine that perform the closing of filled capsules by utilizing its ejection pins.

Electric Enclosure

The machine also has a large cabinet where electrical devices, mechanical tools, and motor parts are located. This section is known as electric cabinet.

Capsule Seeding Area

It is the capsule sowing device which play major role in capsule orientation. It consists of magazine, sorting needles, and a sorting block. Together, they help in orienting capsules by safely transferring them from hopper till their infusion into bores of capsule station.

Worktable

The worktable includes rotary discs which circulate in front of capsule sowing device and under the material filling head for respective tasks. Over these rotary discs, capsule station or rings are placed which holds empty capsules.

Main Frame

The main frame of machine constitutes support parts which are made from durable stainless steel to avoid machine shaking during operation.

Universal Wheel

The machine also has multiple universal wheels for easy mobilization and placement in suitable location.

8.Differentiate Between Semi Automatic Encapsulation Machine And Fully Automatic Encapsulation Machine?

Semi automatic encapsulation machine and fully automatic encapsulation machine are designed for carrying out the same task. However, both machine different from one another on the basis of several factors. These differences are highlighted in the table below for your understanding:

No	Factors	Semi Automatic Encapsulation Machine	Fully Automatic Encapsulation Machine
1	Definition	Semi automatic encapsulation machine is a machine which is dependent upon operator for its functioning.	Fully automatic encapsulation machine is a standalone machine that can independently carry out the tasks.
2	Structure	Its structure is comparatively compact and simple than fully automatic encapsulation machine.	While as, it has heavy-duty machinery with sophisticated tools and devices.
3	Process	Its process is based on several steps making it long one.	In contrast, it follows smooth and uninterrupted working process.
4	Efficiency	With medium level efficiency, it has output of about 10k to 20k capsules per hour.	On the other hand, it can produce up to 450k capsules with greater efficiency just in an hour.
5	Cost	It is cost-effective.	However, fully automatic encapsulation machine has high initial cost.
6	Application	It is suitable for medium size industries.	It is ideal for large scale production facilities.
7	Picture	AIPAK- CGN-208D Semi Automatic Capsule Filling Machine	AIPAK- NJP-2500C Automatic Capsule Filling Machine

9.What Are The Applications Of A Semi Automatic Encapsulation Machine?

Semi automatic encapsulation machine is widely applicable to multiple sectors with demand for the production of capsules. Some of the prominent ones are highlighted as under:

Pharmaceutical Industry

Softgel & hard gel capsules in blister packs- Picture Courtesy: californianaturalcolor.com

The use of a semi automatic encapsulation machine is inevitable in pharmaceutical industry for the production of capsules containing active ingredients along with excipients. It is useful to meet the growing demand for capsules due to their convenient swallowing.

Nutraceutical Industry

Nutraceutical capsule presentation idea- Picture Courtesy: stock.adobe.com

It is necessary to deliver accurate amount of vitamin, minerals, and protein through supplement capsules. Now, it becomes easily possible with the use of a semi automatic encapsulation machine which precisely weigh and fill capsules in nutraceutical industry.

Herbal Industry

Herbal capsules- Picture Courtesy: healingpharma.in

Herbal capsules are also very popular among masses. In this way, moringa powder, turmeric powder, and ginkgo biloba extract are some of the common examples which can be taken through capsules. Thus, the relevance of the machine come to prominence.

Veterinary Industry

Semi automatic encapsulation machine is also used in veterinary industry for the growing need for making capsules for pets and animals. It becomes another significant application of the machine.

Food Industry

Various food & supplement powders- Picture Courtesy: gfrpharma.com

Food additives and spices are sometimes delivered in form of capsules to avoid over use. Similarly, for their production a safe and cost-effective machine like semi automatic encapsulation machine can be easily used.

10.How Can You Improve The Efficiency Of A Semi Automatic Encapsulation Machine?

Improving the performance and efficiency level of a semi automatic encapsulation machine is pretty easy that only require you to conduct regular maintenance and cleaning. It is only possible if you follow a proper schedule. So, we can help you in this way, by suggesting some tips which include:

User maintaining a semi automatic encapsulation machine- Picture Courtesy: Herun Machinery

Daily Cleaning

Make sure to clean your machine on daily basis. For this, you should disassemble the parts like hopper and take out the ejector pin plate. Wash them with clean water to remove out residues. For rest of machine parts, you can use a damp cloth to disinfect areas like worktable and PLC control panel etc.

Parts Changeover

It is obvious, that long-term working leads to parts damage and wear and tear. But the thing is how you will know that. So, the answer is simply to keep inspecting your machine during operation. Upon finding any defective part, replace timely to avoid further problems.

Lubrication

Since a semi automatic encapsulation machine include mechanical parts like rotary worktable and motor etc., it is necessary to lubricate them well for smooth functioning. In this way, keep in mind to properly remove the old lubricants and then add new to eliminate contamination.

11.Are There Any Support Equipment You Need To Use Alongside Semi Automatic Encapsulation Machine?

Yes, there are several machines you can use alongside your semi automatic encapsulation machine for support. It helps in minimizing waste and time being spent on their individual usage. These equipment are enlisted below:

Capsule Polishing Machine

AIPAK- NFJ-150 Capsule Polisher

It refers to the machine used for inspecting capsules through different ways such as removing dust particles left over capsules and sorting the capsules by rejecting light weight, empty, and broken capsules. Capsule polishing machine is an important equipment that can be used alongside a semi automatic encapsulation machine.

Capsule Counting Machine

AIPAK- APC-12 Automatic Tablet Counting Machine

Capsule counting machine is another significant apparatus required for the accurate counting of filled capsules. It eliminates the need for human labor and errors of counting. Thus, large number of capsules are perfectly counted by this machine.

Blister Packaging Machine

DPP-260H2 High Speed Alu-Alu Automatic Blister Capsule Packaging Machine

Blister packaging machine can also be used alongside a semi automatic encapsulation machine to pack the finished capsules. It beautifully pack the capsules in blister packs and ALU-ALU packs through which the shelf life and integrity of capsules can be preserved for longer time.

Strip Packaging Machine

AIPAK- APK-SP400 Automatic Strip Packaging Machine

Strip packaging machine is another equipment you can integrate with a semi automatic encapsulation machine. It is a cost-effective and convenient way to pack capsules in flexible strip packs which give them protection against moisture, light, and air.

12.How To Determine The Production Capacity Of A Semi Automatic Encapsulation Machine?

Capsules production- Picture Courtesy: Freepik

This question carry great significance for capsule manufacturers who are concerned about the production capacity of a semi automatic encapsulation machine. Generally, the capacity of a machine can be determined by first looking into its automation level and then the specifications of that machine.

In case of a semi automatic encapsulation machine, as it is semi automatic, so, the production output is on medium level. However, going further into its specifications, we may find that it can produce around 10k to 20k capsules in an hour. This difference in production output is marked by the machine design such as single head or double head semi automatic encapsulation machine.

13.How To Control The Quality With A Semi Automatic Encapsulation Machine?

Quality control icon- Picture Courtesy: medium.com

Maintaining the quality of a semi automatic encapsulation machine is of key importance. Thus, you should be concerned in this way. However, we can suggest you few things which if followed will definitely help you in controlling the quality of your semi automatic encapsulation machine. These include:

Buy a machine which is made up of stainless steel, so, there will be no chances for bacteria or corrosion to contaminate the production process.

Brand new machine is the assurance that you can have the safe processing both in terms of machine performance and its hygiene.

Keeping your machine well cleaned and maintained all the time can significantly improve the quality of your production which can ultimately boost your profit.

Make sure the machine you purchase is tested and certified by internationally recognized quality standards.

14.What Are The Quality Standards For A Semi Automatic Encapsulation Machine?

In order to get an outstanding semi automatic encapsulation machine, it is significant to check the machine's quality and that can be checked by looking into the machine's adherence to certain quality standards which include:

Various quality standards

Good Manufacturing Practices (GMP):This certification represents that the machine is following updated regulations about machine safety such as construction material and other aspects.

International Organization for Standardization (ISO):ISO develops strict principles regarding the quality of machines like Quality Management Systems (QMS) is ISO 9001:2015 whose compliance is mandatory for a semi automatic encapsulation machine.

Food and Drugs Administration (FDA):FDA is USA based agency aiming at preserving the health safety and well being of public for which regulations are made for drugs and relevant machines.

Conformate European (CE):It represents the collective safety concerns of European Union countries. Thus, having a machine certified by CE will show its recognition there.

15.How To Solve The Common Issues Of A Semi Automatic Encapsulation Machine?

When operating your semi automatic encapsulation machine, it is for sure that at any point you may find it as not functioning properly due to the occurrence of any issue. These issues are most of the time simple one which can be tackled easily once the root cause is found. So, let's know their troubleshooting!

Capsules stuck during orientation

Capsule stuck during orientation- Picture Courtesy: capsugel.com

Cause:

The gate of capsule seeding mechanism open too early, causing two capsules to enter the holder.

Misalignment of the filling ring with capsule seeding mechanism leads to blockage

Solution:

Adjust the capsule sorting device to align capsules in the mid area for smooth orientation.

Align the filling ring with capsule seeding mechanism, so, capsules could pass easily.

Empty capsules opening failure

Capsule opening failure- Picture Courtesy: Freepik

Cause:

Inadequate supply of vacuum for separation of capsule cap and body.

The capsules used are either defective or their size is not appropriate.

Solution:

Provide sufficient vacuum to let the capsules open properly.

Change the capsules and use accurate size capsules.

Inconsistency in fill level

Inconsistencies in filled capsules

Cause:

The fill level of hopper is low which leads to slow discharge of material.

Disparity between the speed of filling ring or capsule plate and the auger head.

Worn out or defective parts can also be one of the reasons for nonuniform material filling.

Solution:

Refill the hopper by loading material into it.

Adjust the speed of auger head to that of rotary capsule plate.

Replace the damaged parts with new one.

Capsules get damaged

Loose capsule- Picture Courtesy: freeimages.co.uk

Cause:

The capsules are either too loose or sealed too tight.

Overdosing also causes capsule breakage.

Solution:

Modify the capsule sealing force to suitable level.

Adjust the speed of capsule plate along with fill volume to solve the issue.

16.What Are The Technology Advancement Of AIPAK Semi Automatic Encapsulation Machine?

AIPAK logo- Picture Courtesy: AIPAk Pharmaceutical Equipment

AIPAK semi automatic encapsulation machine offers range of technology advancements which can be easily understood under the following headings:

Production Capacity

It has excellent production capacity which is a bit larger than the machines available in market today. It can produce 20,000 to 25,000 in an hour without requiring any need for parts changeover.

Fill Material Type

It supports the filling of all kinds of dry and solid material into capsules encompassing powders, granules, pellets, and small tablets.

Models

Within AIPAK semi automatic encapsulation machine inventory, you can have the option to get different models such as AIPAK single head semi automatic encapsulation machine and double head semi automatic encapsulation machine.

Warranty & Certification

Capsule encapsulation machine by AIPAK comes with one year of long warranty which validates its quality. In addition to it, you will get the obligatory quality standards certification such as GMP, CE, and ISO.

Integration of Support Equipment

Not only our semi automatic encapsulation machine support the integration of support equipment but we also offer multiple machines such as blister packaging machine, capsule sorting machine, capsule polishing machine, bottling machine, and counting machine etc.

17.Tips For Selecting The Best Semi Automatic Encapsulation Machine?

Selecting right semi automatic encapsulation machine for your business can be instrumental as it offers myriad of benefits offering both the automation and manual control. However, few factors must be considered to get the ideal solution for which we have given some tips. These include:

Production Output

Large number of capsules- Picture Courtesy: Shutterstock

Firstly, it is very important to look for your production needs as semi automatic encapsulation machine offers different output ratio. For instance, double head semi automatic encapsulation machine has higher output then single head machine.

Compatibility

Different sizes of capsules- Picture Courtesy: emsdiasum.com

You should also check in advance the machine's compatibility with different sizes capsules or else it may damage capsules with different sizes. If you want to fill multiple sizes of capsules then it is wise opt for the machine which has option for interchangeable tools.

Quality

Quality written on wooden cubes- Picture Courtesy: culturewise.com

Always go for the machine produced with high quality material. Such machines will ultimately have durable construction, long working life with warranty policy and necessary certifications of qualification.

Convenience

It is advisable to look for a semi automatic encapsulation machine which is simple in its construction with easy way of loading and unloading. It is necessary to consider because complex procedures often tend to cause delay and production hitches. 

Conclusion

To wrap up this buying guide about Semi Automatic Encapsulation Machine, we hope you get answers to all your questions. Remember that buying a semi automatic encapsulation machine is one of the best choices you can made for your production whether is it pharmaceutical industry, herbal or any other related field. It offers multiple benefits with cost-effectiveness, simplicity and efficiency. If you are interested in purchasing a high quality semi automatic encapsulation machine, then AIPAK is the best suitable option offering wide array of machines. For further information you may contact us through our website!