Dosator Capsule Filling Machine

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Z Series Dosator Capsule Filling Machine

Dosator Capsule Filling Machine: The Ultimate FAQ Guide

All information you’re looking for about dosator capsule filling machine is right here.

From components, working principle, specification to support equipment, among other vital aspects.

So, if you want to be an expert in dosator capsule filling machine, this is the right guide for you – keep reading.

What is a Dosator Capsule Filling Machine?

This is a machine that will fill products inside hard-shelled capsules.

It uses a dosator to fill these products reliably and effectively.

Dosator capsule filling machine

Dosator capsule filling machine

What are the Components of the Dosator Capsule Filling Machine?

This machine comes with several components that all work together to achieve the best filling process.

These parts may vary from one machine or manufacturer to another.

Here are the components that make up a dosator capsule filling machine:

Conveyor System

It has rails that will assist in transporting the capsules from one part of the machine to the next.

Sensors

These automatic components will assist in detecting faults with the dosator capsule filling machine.

It will also reject faulty fillings and capsules.

Also, it will sound an alarm to warn the operator of any malfunctions.

Besides, in extreme cases, it can automatically stop the dosator capsule filling machine from operating.

This will save a lot of resources and minimize damages.

Motors

 Electrical system if dosator capsule filling machine

 Electrical system of dosator capsule filling machine

These components will convert electrical energy into mechanical energy.

This mechanical energy will drive the parts of the machine such as the conveyor system.

Control Panel

This is a central station where the operator can monitor and input filling parameters to the machine.

It comes with a programmable logic controller [PLC] and a human-machine interface [HMI].

The graphics display and the buttons make it easy to use.

Pneumatic Unit

This part will provide the necessary pressure that sucks and ejects the powder that goes into the capsules.

Lubrication Unit

This unit is available on automatic dosator capsule filling machines.

It automatically applies grease on the moving parts hence minimizing friction.

This will reduce the tear and wear of these components.

Electrical System

It holds all the electrical components such as fuse, power plug, etc.

This system will supply power to the dosator capsule filling machine for it to operate successfully.

Dosator Cavity

This space will hold the powder before filling it into the empty capsules.

The cavity size varies from one machine to another and the filling prescription.

Dosing Unit

Dosing unito f dosator capsule filling machine

Dosing unit of dosator capsule filling machine

This part will assist in filling the correct amount of powder material into the dosator cavity.

It comes with pistons that will apply pressure on the filling powder forming a slug.

Dosator Plunger

It holds the entire dosator filling equipment that will get into the powder during the filling process.

A dosator plunger will apply pressure on the machine that will hold powder.

Capsule Hopper

This component will hold all the empty capsules that the machine will use.

The machine will sort these capsules as the production process begins.

Dosator Pin

This pin is at the tip of the dosator filler unit.

It has a cavity that will fill with powder once it gets into the powder.

Dosator dosing system

Dosator dosing system

Powder Hopper

This is the part that will hold all the powder that will go inside the capsules.

The operator can fill different types of powder depending on the filling specification.

How does Dosator Capsule Filling Machine Operate?

Different dosator capsule filling machines work in different ways depending on the technology and filling materials.

The stages of how this machine works include:

Preparation Phase

In this stage, ensure the machine is in good working condition by inspecting all the components.

Make sure to fill the powder material and the empty capsules at their respective hoppers.

Input all the filling parameters via the control panel and start the machine.

Incoming Phase

The dosator begins with moving into the powder bed in a vertical position.

This downward motion will enable the powder material to fill into the dosator cavity.

Also, the size of the dosator cavity is dependent on the dosator plunger.

Compaction Phase

 How dosator capsule filling machine works

 How dosator capsule filling machine works

In this phase, the dosator capsule filler compacts the powder material inside the dosator cavity.

Compression of the filling material inside the dosator cavity happens with the assistance of the dosator plunger.

More space will be available to fill additional material inside the dosator cavity.

Retraction Phase

The dosator plunger moves out of the filling material once the dosator cavity is full.

It then moves towards the filling station as it gets ready to fill an empty capsule.

Concurrently, empty dosator pinheads to the power station to start the process.

Doctoring Phase

Doctoring is a technique whereby the machine removes excess filling material from the dosator pin.

This ensures the right amount of powder will fill the empty capsules.

Ejection Phase

In this phase, the machine releases the powder material into the empty capsules.

The empty capsules move from the hopper via the conveyor belt into the filling station.

Also, it removes the caps from the main body ensuring it is open and ready for the filling process.

Vacuum systems in the dosator capsule filling machine assist with the separation of the caps from the body.

The machine automatically ejects the powder material into the empty capsules.

After the dosator filling process, the machine automatically places the caps on the body.

Thereafter, it locks the caps in place making them ready for inspection.

What Products can you Fill in Capsules using a Dosator Capsule Filling Machine?

There are several materials you can fill inside capsules using a dosator capsule filling machine.

The material a company will fill depends on the prescription they intend to manufacture.

There are instances where you can fill more than one material inside a capsule.

Materials you can fill using a dosator capsule filling machine are:

  • Powder
  • Granules
  • Tablets
  • Pellets

What should you Consider when Choosing Dosator Capsule Filling Machine?

It might be a daunting task when it comes to choosing a dosator capsule filling machine.

This is because there are several manufacturers and the machines come with varying features.

Here are some factors that will assist you when choosing a dosator capsule filling machine:

 Dosator capsule filling

 Dosator capsule filling machine

Type of Filling Material

There are various substances you can fill inside capsules.

Ensure the machine is capable of filling these materials with minimal changes.

Dosator Cavity

Capsules come in different sizes.

Ensure the machine can fill the right amount of filling material on any capsule size.

The dosator cavity will determine the amount of filling material it can hold.

Filling Accuracy

Select a dosator capsule filling machine that leaves minimal to no room for error during the filling process.

This will save you resources and capital.

Capsule Size

Ensure the machine can fill any capsule size that you intend to fill in your production line.

Changeover

Choose a dosator capsule filling machine that can handle changeovers easily to accommodate the changing filling needs.

Filling Rate

This is the number of capsules the machine can fill per unit time.

Fully automatic machines will fill several capsules per unit time than semi-automatic dosator capsule filling machines.

Automation

The level of automation you require will determine the kind of dosator capsule filling machine you will purchase.

Fully automatic machines are more reliable, time-saving, and efficient than the semi-automatic or manual version.

Capacity Hoppers

Ensure the powder hopper will hold adequate amounts of filling material without the need for frequent refilling.

Also, make sure the capsule hoppers also hold a sufficient amount of empty capsules.

This will save you time during the filling process.

Brand

Ensure you purchase a machine from a brand you trust and offer high-quality machines.

This is a factor worth considering than just how good the machine might look.

It might cost you much initially, but the investment will be worth it in the long run.

Quality Standards

It is vital to select a dosator capsule filling machine that meets all international quality standards.

This is to ensure the safety of operators and the products.

Also, it ensures the reliability, effectiveness, and acceptability of the production process in the market.

Construction Material

Choose a dosator capsule filling machine that is of durable stainless steel.

This ensures it performs optimally and will last for long.

Besides, they are easy to clean and maintain, thus saving you a lot in the long run.

Budget

The amount you have will influence the type of dosator capsule filling machine you can afford.

Besides, choose a machine that will meet all your production needs without compromising on quality.

Technical Specifications

This information is available for every dosator capsule filling machine you would want to purchase.

Ensure that the description will meet your production needs.

Also, involve an expert to assist you choose the suitable dosator capsule filling machine.

Technology

Technological advancements are happening all the time.

The level of technology that a dosator capsule filling machine has will influence its effectiveness.

Besides, good technology allows you to achieve the best filling processes.

Also, it allows you to be at par with the market standards.

Efficiency

Always purchase a dosator capsule filling machine that will produce quality filling processes.

Configuration of Machine

Dosator capsule filling machines come in different designs and sizes.

Purchase a machine that will comfortably fit your work area.

Commercial dosator capsule filling machines require a large work area than small scale machines.

Maintenance

A dosator capsule filling machine that is easy to maintain and repair will benefit your industry.

Also, ensure the spare parts are easy to acquire in the market.

Besides, being able to replace parts easily will minimize downtime during the filling process.

What Capsule Sizes can you Fill with a Dosator Capsule Filling Machine?

Capsules come in different sizes and will influence the material it can hold.

The capsule capacity will vary from 0.13 ml to 28 ml.

Here is a look at the list of various sizes of the capsule shells and their approximate volumes:

Capsule sizes

Capsule sizes

  • 5

This is the smallest with a volume of 0.13 ml.

  • 4

Its volume is 0.20 ml.

  • 3

It has a volume of 0.27 ml.

  • 2

This comes with a capacity of 0.37 ml.

  • 1

Its volume is 0.48 ml.

  • 0

Normally, this comes with a volume of 0.67 ml.

  • 0E

It has a capacity of 0.7 ml.

  • 00

This has a capacity of 0.95 ml.

  • 000

It holds a capacity of 1.36 ml.

  • 13

It has a capacity of 3.2 ml.

  • 12

Its capacity is 5 ml.

  • 12el

This holds a volume of 7.5 ml.

  • 11

It holds a volume of 10 ml.

  • 10

It holds a volume of 18 ml.

  • 7

It holds a volume of 24 ml.

  • Su07

This is the largest capsule size and holds a volume of 28 ml.

What are the Features of Dosator Capsule Filling Machine?

These are the features that make a dosator capsule filling machine unique.

They include:

  • Comes in a reliable and compact body design
  • Provides fast and accurate dosing
  • Complies with international standards such as GMP and CE
  • It comes with rotating scales that make the dosing adjustment to be easy
  • Comes with a high production capacity
  • It can fill individual or a combination of materials such as powder, pellets, granules, and tablets
  • It comes with a durable S.S 304 and 316L stainless steel structure
  • A control panel allows for ease of monitoring
  • FDA approves the material of choice that makes the machines
  • Easy to maintain and repair
  • It can work with other support equipment in the production line

What are the Technical Specifications of a Dosator Capsule Filling Machine?

These technical specifications will vary from one machine to another.

This is because different manufacturers will try to make the machines different from their competitors.

Here are some of the technical specifications you can find:

  • Has a maximum output capacity of between 25000 to 200000 capsules per hour
  • It requires a voltage capacity of 230 V up to 400 V, with 50 Hz or 60 Hz
  • The compressed air needs maybe 50-6 bars or 100-6 bars of liters per minute.
  • The machine can weigh up to 2.3 tonnes.
  • It works with a vacuum capability of 100-20 mbar.
  • The maximum power installation can go up to 14 kW.
  • Caan fill capsule sizes ranging from 5 to 000L.
  • It can handle between 4 and 30 capsules per cycle.

What are the Various Types of Capsule Filling Machines available in the Market?

There are numerous capsule filling machines in the market today.

The one you choose depends on the manufacturing requirement and the number of capsules you need to make.

Three types of capsule filling machines exist, and they are:

Manual or Hand-operated Capsule Filling Machine

This is suitable for individuals or industries whose production capacity is low.

These machines can produce up to 800 capsules per pressing.

Manual capsule filling machine come with loading trays that can have around 300 cavities.

Also, a powder tray is on the machine.

A pin plate will act both as a filter and a sealing unit.

The machine also has a handle that assists in filling the capsules.

Among these three capsule filling machines, it is the slowest.

Besides, an operator has to be present for it to work.

Semi-automatic Capsule Filling Machine

This is a hybrid between a fully automatic and manual capsule filling machine.

Also, it needs fewer operators during the filling process.

The design of a semi-automatic capsule filling machine allows it to meet the hygienic standards that are necessary for pharmaceutical industries.

It is durable and low maintenance due to its good design and strong construction.

Stainless steel makes the bulk of this machine.

Non-corrosive elements make it easy to clean after use.

Fully Automatic Capsule Filling Machine

This machine has the capability of performing the entire capsule filling process with no operator present.

They are suitable for large commercial industries.

Also, they can fill multiple materials in capsules.

Besides, you can incorporate support equipment with this machine.

It is the most expensive, time-saving, and reliable of these three machines.

How does a Semi-automatic and Fully Automatic Dosator Capsule Filling Machine compare?

 Dosator capsule filling machine process

 Dosator capsule filling machine process

Depending on your production needs, you will either choose a semi-automatic or a fully automatic dosator capsule filling machine.

Fully automatic dosator capsule filling machines are more expensive than semi-automatic dosator capsule filling machines.

A fully automatic dosator capsule filling machines are easy to operate than a semi-automatic dosator capsule filling machine.

A single operator can easily monitor and operate a fully automatic dosator capsule filling machine.

On the contrary, a semi-automatic dosator capsule filling machine needs some operators to monitor for a successful operation.

A fully automatic capsule filler has systems that automatically lubricate the moving parts easily.

This reduces downtime for maintenance while minimizing the tear and wear of these parts.

In a semi-automatic dosator capsule filling machine, the operator will need to perform this task regularly.

A fully automatic dosator capsule filling machines have high filling capacities than semi-automatic dosator capsule filling machines.

A fully automatic dosator capsule filling machine is also large and has more components than a semi-automatic dosator capsule filling machine.

It is easy to integrate a fully automatic dosator capsule filling machine into an automatic production line from raw materials to final products.

The hoppers in fully automatic dosator capsule filling machines are larger than those of semi-automatic machines.

This allows the operation to continue for a long time requiring less time for refilling.

What are the Applications of Dosator Capsule Filling Machine?

Several industries use this machine in their production line, and they are:

  • Pharmaceutical industries
  • Cosmetics industries
  • Nutritional industries
  • Biotech industries
  • Health supplement industries
  • Food product industries

How do you Maintain Dosator Capsule Filling Machine?

Maintaining a dosator capsule filling machine ensures that it works properly and is durable.

Repair and replace faulty electrical components to avoid electrical shocks and fire hazards.

Conduct regular inspections either quarterly or semi-annually to ensure all parts are in good working conditions.

Lubricate all moving parts to minimize tear and wear.

Repair and replace faulty sensors and fuses to ensure the machine operates optimally.

Clean the machine and the sensors regularly to avoid the build-up of dust and moisture from the environment.

Replace broken and faulty motors with new ones to ensure a smooth operation.

Use genuine parts when replacing components to ensure the machine will not break down during operation.

How does Soft Gel Encapsulator compare to Dosator Capsule Filling Machine?

These two machines have both similarities and differences.

Both of them can fill capsules at high speeds.

They can also achieve the highest level of accuracy during the filling process.

Also, stainless steel makes up the bulk of these machines.

Dosator capsule filling machines are suitable for hard-shelled capsules.

However, soft gel encapsulators are suitable for filling soft gelatin capsules.

Dosator capsule filling machines will fill powders, capsules, tablets, and granules on hard-shelled capsules.

Soft gel encapsulators are suitable for filling suspensions and liquids.

How does Dosator Capsule Filling Machine compare to Tamping Pin Capsule Filling Machine?

Both of these machines can fill hard gelatin capsules.

Also, in both these machines, the powder has to turn to a slug before filling it in capsules.

They can both handle different capsule sizes during the filing process.

Besides, they can fill powders and pellets in capsules.

They both offer fast, accurate, efficient, and reliable filing processes.

However, a dosator capsule filling machine is suitable for filling micro-dosings powder on capsules.

Dosator capsule filling machines can come in manual and automatic versions.

This means you can purchase one with the budget you have.

On the other hand, a tamping pin capsule filling machine is only available in automatic versions.

Besides, they both have different operational principles.

Tamping pin capsule filling machine

Tamping pin capsule filling machine

 Dosator capsule filling machine

Dosator capsule filling machine

What are the Benefits of using Dosator Capsule Filling Machine?

A dosator capsule filling machine has several benefits such as:

Support Equipment

It is possible to incorporate other support equipment with this machine.

Changeover

The machine can do an automatic changeover depending on your production parameters.

Accuracy

Also, it is very accurate, reliable, time-saving, and can achieve high production capacities.

Sensors

Automatic sensors will prevent damages, hazards, and loss during the filling process.

Single Part Adjustment

The operator can easily adjust parts independently.

Production Capacity

It is possible to use it in large production plants since it comes with high production capacities.

Versatility

The machine is capable of filling low weight capsules sizes.

What are the disadvantages of a dosator capsule filling machine?

The disadvantages of this machine should not deter you from purchasing one.

They include:

Price

The level of technology will determine the price of this machine.

Fully automatic versions will cost more than semi-automatic and manual machines.

Power Consumption

Large commercial dosator capsule filling machines require a lot of power thus increase your overall production cost.

Capsule Type

Dosator capsule filling machines are suitable for hard-shelled capsules and not soft gel capsules.

Filling Material

It is only possible to fill powder and solid products with a dosator capsule filling machine.

This means you need another machine if you need to fill liquid substances in capsules.

Expertise

The operator needs to have some knowledge on how to operate a dosator capsule filling machine.

This means you need to spend time and money to train the staff.

Portability

The size of dosator capsule filling machines makes them difficult to relocate from the initial work station.

How do you use a Dosator Capsule Filling Machine to Manufacture Low Fill Weight Capsules?

It is possible to fill low fill weight capsules by adjusting the nozzle of the dosator.

The capsule’s diameter should match that of the nozzle to fill it accurately.

What are the Types of Dosator Filling Systems?

The three types of dosator filling systems are:

Intermittent Machines

Several industries use this machine.

The dosators go into the powder, fill the cavity, and undergo ejection on capsules.

Continuous Dosator Machines

In this model, the dosator has a turret that has a smaller diameter than the circular powder trough.

The turret and the bowl rotate in a similar direction.

Enhancements Dosator Filling Machines

These have innovative features that improve the performance of the machine.

What are Some Filling Trends in Dosator Capsule Filling Machine?

The trend in the pharmaceutical industry is to get rid of the carrier within blends.

Also, it involves manufacturing small doses of API that goes into respiratory tracts.

What are the Powder Filling Systems in Pharmaceutical Industries?

The powder filling systems include:

Direct Filling Systems

Examples include:

  1. Auger-filling principle
  2. Vibration-assisted filling

Indirect Filling Systems

Examples include:

  1. Tamping filling systems
  2. Dosing wheel
  3. Dosator nozzle machines
  4. Hot-melt extrusion principle

What Quality Standards should Dosator Capsule Filing Machine conform to?

A dosator capsule filling machine complies with quality standards to ensure safety, reliability, and quality.

The quality standards that it has to conform to are:

Current Good Manufacturing Practice [cGMP] Quality Standard

This quality standard ensures the machine uses proper design, control, and monitoring of manufacturing processes.

Adhering to cGMP assures the strength, quality, identity, and purity of the capsules.

Restriction of Hazardous Substances [RoHS] Quality Standard

This quality standard ensures that no specific hazardous materials are on the machine.

It ensures the machine is environmentally friendly and does not cause any pollution.

European Union CE Marking

All companies in the world accept this quality standard even though it applies to European Economic Areas.

SS AISI 316 Compliant

This ensures the machine uses authentic stainless steel that is durable.

Food and Drug Administration [FDA] quality standard

FDA will protect public health by ensuring safety, efficiency, and secure drugs and biological products.

What is Volumetric Capsule Filling Process?

This is a technique where the machine fills granules and pellets by using gravitational force.

What Troubleshooting Techniques can you use with Dosator Capsule Filling Machine?

Troubleshooting assists you detect and solve problems that the machine may encounter.

Here are some troubleshooting techniques:

Damages to Capsules

This damage can happen courtesy of the tooling system.

Solve this problem by calibrating the machine.

Also, grease all moving components.

Body and Cap do not Separate

The vacuum system may fail to handle the separation process.

Adjust the vacuum separation unit to solve this problem.

Inconsistency during Filling

This can be due to the presence of colloids in powders.

Also, improper mixing of the filling material can cause this problem.

Solve this by properly mixing the materials.

What Factors Determine Price of Dosator Capsule Filling Machine?

Multiple factors will influence the price of a dosator capsule filling machine:

Level of Automation

Fully automatic dosator capsule filling machines will cost more than semi-automatic or manual versions.

Brand of Machine

Some manufacturers have a high reputation when it comes to manufacturing dosator capsule filling machines.

Since they have a lot of experience and expertise, their brands will generally cost more.

Place of Origin

Dosator capsule filling machines that come from China will fetch a low price than those from other countries.

Production Speed

Dosator capsule filling machine that can fill several capsules within a short time will cost more.

This is because they can meet your production needs in a relatively short time.

Quantity

Some manufacturers will offer you huge discounts when you are purchasing several dosator capsule filling machines at once.

Design of the Machine

Large commercial dosator capsule filling machine will cost more than small and mid-sized dosator capsule filling machine.

This is because they come with a high production capacity and a lot of automation.

Supply and Demand

The law of supply and demand has been there for a long time.

Businesses will compete for available dosator capsule filling machines when the demand goes up and the supply is low.

This means the price of the machine may go up since it is in high demand.

On the contrary, when the market has an over-surplus of these machines, the price will reduce as demand is low.

Market Conditions and Economy

When market conditions are unfavorable, the machine may fetch a lower price as buyers will not pay a higher price.

This may be due to political tension or ethical and tribal differences.

Discounts and Sales

A dosator capsule filling machine that has a price cut will make you spend less when purchasing them.

Model and Features

It is easy to sell standard than it is to sell specialized dosator capsule filling machines.

A model that has outstanding features will demand a high price.

Condition

If the machine is in poor condition, it will not fetch a better price.

Besides, old machines that are well-maintained will sell for a better price.

A machine that has undergone several repairs and maintenance will fetch a low price since it is not that reliable.

Age

The age of a dosator capsule filling machine will influence its price as they depreciate over time.

As time goes by, the machine may be outdated as new and efficient dosator capsule filling machines emerge.

Ability to Inspect and Test

Being able to inspect and test the machine in person will make a huge difference in the price.

Seeing the condition and its ability to fill, means you can negotiate the price adequately.

What is the Cost of Dosator Capsule Filling Machine?

This machine will cost anywhere between 300 US dollars and 160000 US dollars.

What Support Equipment can you use with Dosator Capsule Filling Machine?

These are machines that can work hand in hand with a dosator capsule filling machine.

Also, they will work well with hard-shelled capsules:

  • Vacuum mixer
  • Medicinal mixing tank
  • Capsule inspection machine
  • Colloid mills
  • Capsule sorter
  • Capsule polishing machine
  • Capsule pulverizer

At SaintyCo, we offer a range of dosator capsule filling machines that meet your unique production needs.

Contact us today for all your dosator capsule filling machines.