Predicting your required powder weight(s): Although not necessary, knowing exactly how much powder you’ll use will make the whole capsule-filling process more efficient.
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For example, if you weigh out the powder before filling, you won’t have to use any guess work when it comes time to pour it into the machine. Otherwise, you’d have to keep adding more and more powder as you go. You’ll also more than likely be left with excess powder once they’re full.. which you’ll have to pour back into the container.
Even mixing: If using multiple ingredients to fill your capsules, you’ll want to mix your supplements in a way that ensures even distribution of your active ingredients. This is vital if you want each capsule to hold the same amount, enhancing your final product’s efficacy.
See our article on How to Make Your Own Supplements for the 3 rules of even powder-mixing.
Grinding up larger-particle powders: Adding to mixing properly, a consistent size of particles throughout your mix will allow for smoother filling in your capsule machine. Running thicker-particle powders through a coffee grinder is an easy way to ensure it’ll flow as best possible. For a lot of powder, a high-powered blender (such as a Vitamix) can often combine both the mixing and grinding jobs nicely.
Capsule ingredient type: Select a capsule type that suits the preferences and needs of your target audience. Common options include:
Gelatin: A widely used capsule material derived from animal collagen. It's versatile, easy to handle, and affordable.
Vegetable-based: Plant-based alternatives to gelatin, such as HPMC (hydroxypropyl methylcellulose) or pullulan, are suitable for vegetarians and vegans, respectively.
Consult the manufacturer's guidelines: You’re probably thinking, “Really? They’re recommending I read the instruction manual?”
You’d be surprised at how often we get calls with problems that could have been solved with one look at the instructions that came with the machine… or by watching the video instructions on our How to Use page. Always review and follow your capsule filling machine's manual or instructional materials for optimal setup and usage, as specific procedures may vary between models.
Capsule orientation: If the machine takes separated capsules, make sure they are correctly sectioned for use within the machine – the longer portion of the capsule, also called the “body,” should be placed aside for use with the base, or “body plate.” The shorter portion, “top,” belongs with the “capping plate.” Mixing these up or using the wrong sides is a surefire way to delay you and possibly waste some product!
Test runs: This is much more important for automatic machines, but nonetheless putting a few capsules in a manual press just to make sure you know how to do it before using is a great way to not waste capsules and powder by messing when actually making your product. A short test run with empty capsules can ensure the machine is functioning correctly before introducing supplement ingredients, as well as familiarize yourself with the process.
Use the instruction manual: Yup, again. When learning the machine, keep that manual out and refer to it at every step to make sure your actions line up with the instructions. It’s best practice to also follow along with that machine’s video instructions for any of the steps that may be hard to understand from pictures and text alone. If the manufacturer of your machine doesn’t provide videos for this purpose, consider a capsule filling company that does!
Optimal filling capacity: As mentioned earlier, calculating the maximum capacity of your capsules for the specific ingredient you’re filling with makes it so that you won’t have to do any cleanup involving repackaging unused powder! Overfilling the machine as a result of not knowing how much powder to add may lead to spillage, waste and a mess.
Use a powder scraper and tamper accurately: When filling the capsules with your supplement blend, use a scraper or spatula to evenly distribute the powder among the capsules. This can help prevent spillage and ensure consistent dosing. Then use a tamper to pack as much of the powder in as possible, repeating the scraping and tamping until no more powder can fit inside the capsule body. Make sure to do this along the outer edge of the machine where those capsule holes aren’t as quick to access as the center of the machine’s holes.
Make your capsules in similar batches: Divide your supplement creation process into stages or "batches" for maximum efficiency. For instance, making all turmeric/black pepper capsules in one sitting will be faster than making multiple different supplement powders will. That’s because you won’t have to worry about extra steps like cleaning the machine between batches to prepare for the other powders, or calculating the amount of powder that will fit for each powder used.
Dedicated machines: Like batching, having multiple machines with each one dedicated to only one supplement type will greatly increase workflow efficiency.
For example, let’s say one of the substances you encapsulate regularly can stick to parts much more than others, making it slightly more difficult. Having one pill filler dedicated to the difficult substance and another dedicated to an easier supplement powder makes it so that you don’t have to worry about cleaning between production to remove the debris (because it’s the same product being filled).
This also keeps from having to switch back and forth between dosage shifts, product lines, etc. that require adjustments such as switching the capsule size plates of the Pro-Op 300 Capsule Filling Machine(bn,pt,ja). One machine can be dedicated to a specific capsule size, supplement type, viscosity, or any other attribute that makes sense for your production.
Increased output to cost evaluation: For those that rely on making capsules in their businesses, it’s essential to calculate the cost to benefit ratio for choosing a higher output machine versus a lower output machine and employees to operate it. For example, our Pro Series 400 Hole can do 400 capsules every 5-10 minutes, but it requires pre-separated capsules, which may or may not cost more than joined. Whereas the Pro-Op 300 separates them for you and makes them faster, but ithas significantly more up front costs.
It’s important to consider what it will cost overtime to operate, versus what the higher output machines will cost. Then choose the option that works best for your business in the long term, and has the highest ability to grow with you as your needs do.
Are you looking forward to purchasing a capsule filling machine? It is one of the biggest investments that any pharmaceutical company can do. However, getting a pharmaceutical machine is not the easiest job you can do. Once you are on the market, you will find different models and types. You should carefully analyze them and pick the right one that suits your production needs. Moreover, it must match your budget as well. Here are 8 factors to keep in mind when looking for that perfect capsule machine.
1. Capsule Type and Size
The very first thing you should consider is the type of capsule you are going to fill up. Along with that, you should also determine the capsule size. You can use a capsule filling machine to fill up:
- Hard gelatin capsules
- Softgel capsules
- Vegetarian capsules
Out of these, gelatin capsules are made out of animal byproducts. They contain a higher volume of gelatin, water and preservatives. You can get them in standard sizes 5 is usually the smallest and 000 is the largest.
Softgels come with a smooth exterior. If you are going to fill up liquids, you need to use them. On the other hand, vegetarian capsules use a cellulose instead of gelatin.
You need to take a look at dosage and density of the contents when selecting a type of capsule as well. Larger volumes would require bigger capsule sizes. Based on the selected capsule, you can pick a machine to fill up.
2. Production Output Requirements
Manual capsule filling machines have an output of around 100 capsules per minute. On the other hand, semi-automatic capsule filling machines can offer up to 100,000 capsules per hour. A semi-automatic machine is mostly okay for your needs. But if you have a higher production output requirement, you may proceed with a fully automatic machine.
However, you need to keep in mind that semi-automatic capsule production machines come at a higher price tag. This is where you need to compare your return on investment.
Automatic capsule fillers are ideal for pharmaceutical producers filling thousands to millions of capsules daily. Lower capacity semi-automatic or manual fillers may suit nutraceutical companies with smaller runs.
3. Level of Automation
Capsule filling machines come in manual, semi-automatic or fully automatic versions. Manual capsule fillers involve entirely hand-operated filling. This is where the operator separates capsules by hand. Then you will need to fill powders/liquids manually and close capsules by hand. They allow small batch production with maximum flexibility. That’s because you will have to spend a lot of time filling up the capsules through this method.
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Semi-automatic machines automate some functions in the capsule machine. They include dosing and tamping but require manual capsule loading/unloading. Such semi-automatic machines offer faster outputs for small to medium batches. Fully automatic capsule fillers integrate all functions. You can use them to automate:
- Orienting of the capsules
- Capsule filling
- Closing and ejecting of capsules
As a result, you can proceed with producing high volumes with speed and precision. Automatic units are ideal for large pharmaceutical and neutraceutical production runs.
4. Adjustability and Customization
It is better if you can spend to buy an adjustable capsule filling machine. Then you can accommodate different capsule sizes. In other words, you will be able to have better production flexibility.
It is a good idea to pick a machine that allows easy size changeovers. Moreover, you can also pick a machine that offers additional dosing stations. Such customized features can make your life easy as you produce capsules.
5. Powder/Liquid Handling Capabilities
You need to keep the type of capsule filler in mind when selecting a filling machine. It can be:
- Powder
- Liquid
- Combination of both
To fill up a capsule with powder, it requires a special system. They will enable filling up the powder precisely into the capsule. Moreover, these systems make sure that the dry powder remains consistent in the capsules.
On the other hand, liquid capsule fillers come with a pump and nozzle system. They inject the liquids directly into capsules. These machines keep track of accurate filling volumes at all times.
Some advanced capsule fillers handle both powder and liquid filling. Alternatively, you can purchase separate powder and liquid capsule filling machines.
6. Cleaning and Maintenance Needs
After getting the capsule filling machine, you will have to clean it regularly. Some of the machines require manual cleaning. But it is better if you can invest in a machine with automatic cleaning. They have the Clean In Place (CIP) technology as well. This allows you to clean the machine without disassembling it.
7. Electrical Requirements
Based on the region, you will either have 110V or 240V at your production plant. You need to pick a capsule filling machine that you can operate as per the electrical input you can provide.
If you operate in an area with unstable electricity, always go for a system with a UPS. Then you will be able to overcome blackouts and ensure consistent production.
8. Investment Budget
The type of capsule filler suitable for you ultimately depends on your production scale and budget. Manual and semi-automatic powder or liquid fillers start around $5,000 to $10,000. Fully automatic pharmaceutical-grade capsule fillers range from $50,000 up to $500,000+ for high-end integrated machines with custom features. Define your budget constraints during the selection process to narrow viable options. Weigh required automation levels against capabilities and cost.
Getting a capsule filling machine is an investment. This is why you need to evaluate ROI when making a decision.
Frequently Asked Questions
Now you have a basic overall idea about buying a capsule filling machine. However, you may still have some unanswered questions on your mind. Follow this section and we will share answers to those questions as well.
What is the cost of a capsule filling machine?
It depends. If you buy a manual capsule filling machine, you don’t have to spend a lot. However, semi-automatic and fully automatic capsule filling machines are quite expensive.
For example, a manual capsule filling machine can cost you around $10,000. On the other hand, fully automatic pharmaceutical grade machines can cost more than $500,000. You should be ready to invest around $50,000 to $100,000 to purchase a decent capsule filling machine. Define your budget beforehand and then look around for the options. It will make life easy to pick the right product.
Should I buy a used capsule filling machine?
If you can’t afford the cost of a new capsule filling machine, going for a used one may seem the best option. However, there are benefits and drawbacks to evaluating when making this decision. For example, you will need to see the condition of the capsule filling machine you get.
Some of the pharmaceutical companies mandate new equipment only. If you are working with such a company, you should be willing to invest in a new machine. But if such a requirement is not there, you may start off your business with a used capsule filing machine. It will help your business save some capital. You can upgrade to a newer and better one as your business proceeds.
What production rates do different capsule filling machines offer?
Production rate is one of the key factors that determine your choice of getting a capsule filling machine. Some of the prominent production rates you can expect include:
- Manual: <1,000 capsules/hour
- Semi-automatic: 1,000 - 40,000 capsules/hour
- Automatic: 40,000 - 100,000+ capsules per hour
It is completely up to you to evaluate these production rates and pick the right filling machine. Then you can use it to run your business without any issues.
How quick are size changeovers on capsule machines?
The changeover time of a basic capsule filling machine is around 15 minutes. However, semi-automatic capsule machines can offer up to two hours. A good thing about semi-automatic capsule filling machines is that they offer tool-free change parts. As a result, you can experience faster changeovers between the runs.
What tolerances to capsule fill weights can I expect?
At the time of buying a capsule filling machine, you need to be aware of filling weights as well. The average weight tolerances of a capsule filling machine include:
- ±5-10mg for powder filling
- ±50mg for liquid filling
Tighter ±3mg tolerances are achievable on high precision machines.
How much space do capsule filling machines require?
To accommodate a capsule filling machine, you will need to allocate a space of at least 3x4 feet. However, make sure to provide another 2 feet of perimeter to enable operator access and airflow. Some of the new capsule filling machines offer a compact and modular design. You can easily accommodate such a machine. However, larger automatic machines would require up to 400 square feet.
What safety mechanisms should I follow when operating a capsule filling machine?
A capsule filling machine usually comes with a variety of safety features. They include:
- Finger guards
- Emergency stops
- Light curtains
- Protective covers
- Overload detection and many more
Along with the machine, you will receive safety instructions to follow. Make sure to follow them at the time of operating the machine. Then you can ensure safety and operate the machine.
How should I clean the capsule filling machine?
Basic capsule filling machines require manual cleaning. However, advanced machines offer programmable in-place cleaning systems with advanced fillers. You need to look at your preferences and pick the right machine.
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