High Speed Automatic Capsule Filling Machine

Introduction

The NJP series automatic capsule filling machine is an industrial encapsulation platform built for pharmaceutical and nutraceutical production lines. Designed for multi-station solid dosage processing, it fills hard gelatin, HPMC, and pullulan capsules with dry powders, granules, pellets, microcapsules, or tablets.

Rated Capacity: Maximum mechanical output varies by model: 12,000 pcs/h (NJP-200C), 24,000 pcs/h (NJP-400C), 48,000 pcs/h (NJP-800C), and 72,000 pcs/h (NJP-1200C). Actual output depends on capsule size, powder density, and flow characteristics.

Bore Configuration: Station die segments feature dedicated hole arrays per model: 2 holes (NJP-200C), 3 holes (NJP-400C), 9 holes (NJP-800C), and 12 holes (NJP-1200C).

Continuous Running Speed: Recommended operational speed for standard free-flowing formulations is 80% to 90% of maximum capacity to preserve long-term dosage accuracy and wear life.

Sealed Transmission: Driving cams and indexers are housed within a sealed oil bath, with cycling speed controlled dynamically via the HMI touchscreen.

Capsule Sizes: Standard tooling covers sizes 00# through 5# in hard gelatin, HPMC, and pullulan.

Supported Formulations: Accommodates free-flowing powders, low-density granulates, coated pellets, microcapsules, and solid oral tablets.

Cohesive Powders: Fine, hygroscopic, or cohesive powders require verified bulk density of 0.35 to 0.85 g/cm³ and low moisture content of <5.0%. Sample material evaluation is recommended before tooling sign-off.

Feed Assistance: Optional agitating blades and vibratory feed aids are available for powders prone to bridging or rat-holing.

Dosing Weight Precision: Individual fill weight variation is maintained within ±3% for free-flowing pharmaceutical powders and ±4% for herbal or TCM formulations. Values represent individual dosage percentage deviation from target mean weight across 100 consecutive sampling cycles during FAT using a lactose placebo.

Micrometric Tamping Control: Five-stage tamping pin depths are finely adjusted via manual micrometric screws to manage powder slug compression against density fluctuations.

Combination Dosing: The feed zone accepts optional dosing modules for combination fills within a single capsule shell (e.g., powder + granule, granule + pellet, or powder + tablet).

Changeover Times: Complete size-to-size tooling swaps, including removal, installation, mechanical alignment, and trial run, take 60 to 90 minutes. Full product-to-product changeover with wet sanitization takes 120 to 180 minutes.

Toolless Product Contact: Powder hoppers, dosing discs, and wiper arms use quick-release tri-clamp fittings for fast disassembly.

Keyed Tooling: Station die blocks feature asymmetric dowel pins to prevent upside-down or misaligned reassembly.

Standardized Wear Parts: Vacuum cups, silicone wipers, tamping springs, and capsule guides are stocked as standard replacement parts for routine preventive maintenance.

Contact Surfaces: Product-contact components are built from AISI 316L stainless steel polished to Ra ≤ 0.4 μm.

Frame & Enclosure: External cladding and non-contact frames are AISI 304 stainless steel with a satin finish. The processing zone is fully enclosed behind transparent polycarbonate safety doors with silicone perimeter seals.

Safety Interlocks: Safety doors feature magnetic sensors that immediately disengage drive power upon opening. Emergency stop buttons are positioned on the main console.

1. What output should I plan for on real powders?

Plan on 70-85% of the rated figure for typical powders, so an NJP-800C delivers about 34,000-41,000 capsules per hour. Cohesive herbal blends and size 00 capsules fall at the low end.

2. Do I need to buy tooling for every capsule size?

Yes, each size (00#-5#) needs its own die set, and a set typically costs 5-10% of the machine price.

3. How should I plan a pharma validation project with this machine?

Allow 6-10 weeks after delivery for installation, IQ/OQ, and a trial batch, with FAT before shipment shortening the on-site part.

4. What is the lead time?

Standard models ship in 45-60 days from the deposit, and units with combination dosing or special tooling in 60-90 days.

5. What spare parts should I order with the first machine?

Order one set of vacuum cups, silicone wipers, tamping springs, and capsule guides, plus one spare vacuum pump filter. These cover most stoppages in the first two years.

6. What is covered by the warranty?

Typically 12 months from commissioning for manufacturing defects, with wear parts such as wipers, springs, and vacuum cups excluded.

7. Should I choose the weight-control system for my powder?

Add online weight checking when the batch value is high, or the powder is cohesive, because it catches drift faster than manual checks every 15-30 minutes.

8. How can I reduce capsule breakage and locking failures?

Check capsule length tolerance first: a variation above ±0.2 mm is the usual cause of unlocked or split capsules. Then adjust the vacuum within the table's range and replace worn guides every 6-12 months.

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