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ZD-I Automatic Suppository Shell Making Machine

ZD-I Automatic Suppository Shell Making Machine

Description:

ZD-I fully automatic suppository shell making machine is the forming equipment that make piece material into bullet head(torpeto),duck mouth type suppository packing belt by feeding, pre-heated, welding, heating froth forming,making split line,cutting bottom side of triangle. It is the first equipment of product line.

Work Procedure

Two rolls of PVC(PVC/PE) material with diameter∮300mm, inner diameter∮75mm are separately installed on belt–disk which equipped automatic brake system. After clamped tightly by jaw The material are transferred in turn to pre–heated, welding,froth forming die by feeding dolly according to cylinder travel. Heating blow making to suppository belt was as same as the shape of die, welded fastness,free gas leak, thick even,The split line can be made and the bottom side of triangle can be cut according to user’s needs. The material will go under the filling nozzle automatically after eliminate static electricity wait for pouring. The above motion are all completed by pneumatic, controlled automatically by programmable controller.

Main Technical SpecificationsZD-I
Output:7200-9800 granules/hour
Filling volume:0~4g
Central distance:bullet head (torpeto) 17.5mm, duck mouth: 26.25mm
Suppository shape:optional specification, shape. Design and machining according to user’s need
Air pressure0.65Mpa
Gas consumption                               0.8m3/min
Application piece material:PVC, PVC/PE height :60mm- 64mm   thickness: 0.15±0.01
Overall dimensions2100 * 700 * 1300 mm (L * W * H)
Weight of overall machine500Kg

Suppository Machine: The Ultimate FAQ Guide

Everything you’re looking for about suppository machine is right here.

Whether you want to learn about the components, working principle, or features, you will find all information right here.

Keep reading to learn more.

What is Suppository?

A suppository is a solid drug that the patient will insert via their body openings.

This can be the rectum, vagina, or urethra, and the dosage will melt to dispense the drug within the body.

Once the dosage softens and melts, they provide a curing value to the patient.

These dosages come in a variety of shapes and sizes.

Suppository

Suppository

What is a Suppository Filling and Sealing Machine?

This is a machine that will fill and seal a suppository dosage in a series of steps.

These steps include:

  • Forming the cover of the suppository from materials like:
  1. Polyvinyl chloride [PVC]
  2. A combination of Polyvinyl chloride [PVC] and Polyvinylidene chloride [PVDC], or
  3. Polyvinyl chloride [PVC] and Polyrthelene [PE].
  • Filling the suppository shell with the dosage
  • Cooling the liquid dosage within the shell
  • Slicing these dosages into various sizes
  • Sealing the dosage

Which Industries use Suppository Machine?

Several industries use a suppository machine in their production line.

These include:

Pharmaceutical Industries

This is the most common industry that utilizes a suppository machine.

Different types of dosages keep coming up, meaning these industries will keep with the trends in producing suppositories.

Many pharmaceutical industries are adopting manufacturing suppositories as a means of drug administration.

Cosmetic Industries

As an ever-expanding industry, they are adopting the use of suppository machines in filling and sealing products.

These products will assist the body with:

  1. Cleansing properties
  2. Moisturizing capabilities
  3. Providing a freshening effect
  4. Preventing constipation

Food Industries

These industries use a suppository machine as the products they make will have a health benefit to consumers.

Such suppositories contain:

  1. Nutritional value
  2. Herbal benefits
  3. Neutraceuticals

What are the Benefits of Suppository Forming and Filling Machine?

Suppository Machine

Suppository machine

These machines have a lot of advantages in the production line.

They have the capability of conducting a string of production processes independently.

Here are the benefits of suppository forming and filling machines:

· Automation

Using an automatic suppository forming and filling machine has a lot of benefits.

It allows for easy monitoring and controlling the whole process.

Programmable logic controls and human-machine interfaces assist with the production process.

· Hygiene

Since the suppositories go inside the human body, it requires proper handling techniques.

This machine will assist in ensuring you maintain high levels of hygiene during the production process.

· Ease of Use

Operating this machine is easy and does not require much skill.

Operator manuals will guide you on the installation and usage procedures.

· Minimal Monitoring

The machine operated automatically, meaning it requires less supervision.

Once the operator keys in the product specifications, the machine will handle the entire production process.

· Diversification

The applications of a suppository forming and sealing machine are diverse.

This is because you can use it in several industries such as pharmaceutical, health, cosmetic, and health care.

· Accuracy and Reliability

The machine utilizes volumetric pumps that will fill the empty shells through nozzles.

They allow for accurate filling leaving no space for spillage and wastage of the suppository solution.

· A high Rate of Production

A suppository forming and sealing machine will allow you to produce many pieces per unit time.

For instance, the production speed may range from 5000 to 15000 pieces every hour.

The speed depends on the type of machine you have as they come with different technical specifications.

· High Liquid Capacity

Suppositories are in a liquid state before cooling in the shells.

This machine allows you to store large capacities of liquids, meaning you will require less refilling during production.

· Quality Standards

This machine complies with international regulations set by various bodies.

It makes your production plant compliant, and hence you will produce quality products.

Also, it provides health and safety benefits to employees.

· Wastage Prevention

A suppository forming and filling machine operates with no wastage of products.

This allows you to maximize the production of suppositories.

· Cooling Speed Regulation

Since suppositories are of various kinds, they also require varying cooling speeds.

This machine allows the operator to control the cooling speed for the suppositories to uniformly solidify.

· Sizeable

This machine will occupy a relatively small work area in the production plant.

They come in various shapes and sizes that allow seamless incorporation in the production line.

Is there difference between Suppository Machine and Tube Filler Machines?

Yes, there is a difference between a suppository and tube filler machines.

A suppository machine will exclusively fill and seal suppositories.

Also, a tube filler can fill products like toothpaste, multi-vitamins, lotions, pesticides, syrups, etc.

A tube filler machine will fill a wide array of products in various types of tubes.

To fill containers and tubes, you require a tube filler machine.

A suppository machine will provide a cooling effect on suppositories to solidify them.

Tube filling machines do not need to cool the product since it fills semi-solids and liquid products alike.

How do you Choose Suppository Molds?

Suppository mold

Suppository molding system

Choosing suppository molds is vital as it will ensure the patients are comfortable while using the dosage.

Selecting bad suppository molds can bring setbacks to the production plant.

Here are factors to consider while selecting suppository molds:

Scaling Up

Ensure the suppository mold you select will allow you to scale when demands go high.

This allows you to produce suppositories to meet demands easily and in a short time.

Batch Size

Plan the batches that you will fill and seal when considering a good suppository mold.

There are specialized dosages that the patient may use once a year.

This means you should pick a suppository mold to meet that specification hence minimizing waste.

For suppositories that sell frequently, choose suppository molds with several cavities.

Base preferences

Choose a suppository mold that are compatible and that the physicians may prefer.

Ensure the mold:

  1. Works with the base you are using.
  2. Considers patients with sensitivities
  3. Meet various doctors requests

Patient Comfort

Manufacturing a suppository dosage that is easy to use by the patient should be a priority.

Large suppositories may be uncomfortable to use, and they can cause leakages, messiness, and lower patient compliance.

Select a suppository mold that will ensure the comfort of your patients during usage.

API Capacity

Choose a suppository mold that will handle the active ingredients in the right amount.

Select a mold and design a working process that will meet most of your production needs.

The mold does not need to be too small or large when you do not plan to dispense such amounts.

Staff Training

Select a suppository mold that is easy and simple to use by your staff.

This allows for minimal training as long as the suppository base is ready.

Latest Technology

As technology is advancing, select suppository molds that meet the current dosage preparation techniques.

This allows you to fulfill the current trends enabling you to sell and make profits.

Titrating Requirements

Select a mold that is easy to score hence simple to titrate.

The suppository molds should make troches that are easy to evenly split.

Also, the mold should make sizeable suppositories allowing patients to insert many suppositories at a time.

How do you Increase Efficiency Suppository Filler?

Increasing the efficiency of a suppository filler allows the machine to operate optimally.

It will meet all production needs and produce quality suppositories.

Here are ways to increase efficiency:

  • Conduct regular maintenance practices to ensure all parts are working properly.
  • Use the latest technology in your suppository filler.
  • Incorporate numerical and alphanumerical screens for easy control and monitoring.
  • If possible, upgrade to a more automatic suppository filler.

Are there Limitations of Suppository Machine?

Here are some limitations of a suppository machine:

High Cost of the Machine

Suppository machines come in varying price ranges.

It is expensive to purchase fully automatic suppository machines.

Training of Staff

The type of suppository machine you have will determine if you need to train staff.

Some machines are difficult to operate and require a lot of staff training before the production process.

Machine Variation

There are many suppository machine variations available, and this can confuse one when selecting a machine.

Maintenance

It can be hard to maintain some suppository machines due to the heating and cooling that happen.

This can cause some downtimes during the production process.

Production Capacity

Manual suppository machines have a low production capacity than automatic suppository machines.

Losing Skills

Fully automatic suppository machines require minimal to no skill by the operator.

This makes the operators easily replaceable.

Unemployment

Suppository machines are advancing as technology advances.

This makes operators redundant as the machines employ machine learning hence require less monitoring.

Environmental Pollution

There are suppository machines that will produce a lot of noise during operation.

This leads to noise pollution and may damage the operator’s hearing capacity.

What are the Component of Suppository Machine?

Several components work together to ensure the quality production of suppositories.

It is also important for the operator to understand how these parts function.

Here are the components of this machine:

Feeder

This is the part where you will feed all raw materials that makeup suppositories.

Film strips that make suppository shells can be from PVC, PVC + PVDC, or PVC + PE.

A film release unit and transfer element will form the film unwinding system.

The film goes to the film plate and a transmitting clamp will move the film strips.

Molding Unit

This part will fill the suppository liquid into the molds.

A guide wheel rolls the packaging material to the molding area.

Also, a cutting system will shape and slice the suppository shell.

It consists of:

  1. Blowing molds
  2. Heating molds, or
  3. Butt molds

Suppository Filling System

It provides a force to fill the material into a material capacity holder via a pump.

The capacity bucket temporarily stores the materials that you will fill inside suppositories.

Hot water helps in maintaining a warm temperature throughout this process.

This system consists of:

  1. Material capacity holder
  2. Agitator
  3. Stirrer
  4. Filling pump
  5. Circulating pump

Cooling System

They will provide large surface areas to enable the suppositories to solidify after the filling stage.

Chillers will provide the cold temperatures while fans disperse the cool air in this system.

It maintains the temperature between 8 °C and 16 °C.

This system contains:

  1. Cooling tunnels
  2. Cooling fans
  3. Water chillers

Sealing Chamber

This chamber will place additional heat on the ends of the suppositories.

A pneumatic sealing component will apply heat to seal the dosages.

Cutting Units

After filling and sealing, the suppository packages pass via a cutting system.

It cuts the dosages in the right sizes.

Electrical Cabinet

The power of the machine comes from the electrical cabinet.

It contains all the wires and elements that feed electrical power to the suppository machine.

Branding System

This system will place marks and symbols on the dosages.

These include the manufacture and expiry dates.

How does Suppository Machine Work?

This is the process of how a suppository machine works:

Preparation Stage

In this stage, you will feed all the raw material that the suppository machine will use.

This includes the unwinding film that can be from PVC or PE materials.

Film Heating

An unwinding clamp will transfer the film strip to the shell formation stage

Shell Forming

As the film strips reach this stage, they will undergo molding and formation.

The film strip undergoes preheating, forming, and blowing to form the cavity where you will fill suppositories.

Suppository Filling

In this stage, you fill the shell cavities with a homogeneous mixture, which is at 80 °C.

The filling valves are accurate allowing an error of +/- 0.1 grams.

Mixers will continue mixing the mixture while the heater maintains the optimum temperature.

Cutting

Cutting blades will slice the shapes of the suppositories to the precise shapes.

Cooling Stage

The cooling chamber provides a low temperature to cool the suppositories in the shells.

This enables the homogeneous mixture to solidify before moving to the next stage.

Shell Sealing

A sealing system will use pneumatic systems to reheat and seal the shells appropriately.

Trimming and Cutting

The suppository machine will cut the suppositories once again in the correct size and shape.

Finally, the suppositories go to the packaging stage.

What Types of Suppository Machines are there?

Suppository machines come in various designs and capabilities.

Depending on your application, you should choose a suppository machine that will meet your production requirements.

Here are some main types of suppository machines:

Nasal Suppository Machines

They make suppositories that will go into the nasal cavity.

Urethral Suppository Machines

It will exclusively manufacture urethral suppositories.

These suppositories are small in size for ease of use by the patients.

It will assist patients with erectile dysfunctions by allowing more blood to flow in the organ.

Vaginal Suppository Machines

This machine will make vaginal suppositories.

It manufactures it in solid oval shapes, which patients find easy to use.

Once inside the body, they melt because of the heat of the body.

These suppositories help with:

  1. Maintaining vaginal moisture and pH levels.
  2. Healing fungal infections
  3. As contraceptives for birth control

Rectal Suppository Machines

These will produce suppositories exclusively for rectal use.

The suppositories are in the shape of a bullet for easy insertion into the organ.

A rectal suppository machine will:

  1. Cure anal pruritus and hemorrhoids
  2. Eliminate constipation
  3. Administer various medications like sedation, analgesia, antibiotics, etc.

Which Factors should you Consider when Choosing Suppository Machine?

It is vital to have enough information when choosing a suppository machine.

This is because the machines come with different capabilities from various manufacturers.

The factors to consider include:

Budget

The amount you have will influence the suppository machine you can purchase.

Always purchase a suppository machine that will meet all your production needs.

Machine Efficiency

Purchase a suppository machine that is efficient and has minimal room for error.

Size of Machine

Suppository machines come in different shapes and sizes.

Choose a machine that will fit your work environment.

Larger machines will generally require more work environment as they are suitable for large industries.

Quality Standards

To ensure the safety of your staff and quality suppositories, go for machines that meet international standards.

It will ensure the reliability, effectiveness, and acceptability of the machine in the market.

Maintenance

Choose a machine that is easy to maintain and is easy to repair or replace parts.

Besides, ensure the spare parts of the machine is readily accessible.

Level of Technology

Several industries will incorporate machines that have the latest level of technology.

It enables you to achieve high production rates and produce quality suppositories.

What are the Quality Standards of Suppository Machine?

The quality standards will ensure that you meet health and safety measures.

These quality standards include:

  • Certified Pharmaceutical GMP Professional [CPGP] quality standard
  • Current Good Manufacturing Practice [CGMP] quality standard
  • European Union CE mark
  • Food and Drug Administration [FDA] Requirements
  • CCC
  • RoHS

What are the Advantages of Suppository Drug?

Here are some advantages of a suppository drug:

  • It is suitable for use by unconscious patients
  • They are good for dosages that have bad taste and odor
  • It provides alternatives for drugs with less bio-availability
  • Good for dosages that have an irritating effect on the gastrointestinal tract
  • They are good for dosages that portal circulation can destroy

Are there Disadvantages of Suppository Drug?

The disadvantages of suppository drugs include:

  • Manufacturing is difficult than other types of dosages.
  • Drugs that irritate mucous membranes cannot take this form.
  • It requires low-temperature storage conditions as it may melt.
  • Also, it may leak once in the body due to the high body temperature.

Which Types of Suppository Bases can Suppository Machine use?

The base you use with a suppository should not react with the dosage otherwise, it will affect its effectiveness.

Suppository filling and sealing machine

Suppository filling and sealing machine

Liposoluble Bases

These include:

  1. Semi-synthetic fatty acid glycerides
  2. Synthetic fatty acid glycerides

Water-soluble Bases

They include:

  1. Gelatin
  2. Glycerin
  3. Peg

What are the Various Methods of Manufacturing Suppositories?

These methods include:

  • Hand molding
  • Automatic machine molding
  • Compression molding
  • Heat molding

How can you Troubleshoot Suppository Machine?

Being able to troubleshoot the machine will allow you to sort our common issues without many technical skills:

The Machine Fails to Start

Ensure the power cable is in good condition and connects to the machine.

Replace faulty fuses and ensure the touchscreen panel responds to touch.

Suppository Mold is not Heating

Make sure the temperature value is correct.

Ensure the electric heater and the fuse is in good working condition.

Suppository cannot Cool and Solidify

Ensure the cooling fan and the water chillers are working properly.

Auto Mode is not Working

Rest the suppository machine and that all sensors are giving out appropriate signals.

Suppository Machine cannot Reset

Press the emergency stop button severally and ensure the sensors are functional.

Suppository Manufacturing Process is Slow

Make sure the piston seal is working correctly with no leakages.

Ensure enough air enters the machine.

How do you Maintain Suppository Machine?

Maintaining a suppository machine will ensure it works properly and lasts for a long time.

Use hot water with disinfectants to clean the material tank, filling, and circulation pipes.

Add some anti-rust lubricants to the air pressure system’s oil cap.

Regularly clean the air pressure system.

Replace or repair faulty parts with genuine parts.

Regularly clean the photoelectric sensors.

Lubricate all moving parts to minimize the tear and wear of the components due to friction.

Conduct regular check-ups on the entire machine, either quarterly or semi-annually.

How much do Suppository Machine Cost?

The cost of the machine varies depending on its capabilities.

It can go for anything between 3000 US dollars to 1000000 US dollars.

Is there a difference between Urethral and Rectal Suppository Filling and Sealing Machine?

Yes, there is a difference between these two machines.

Urethral suppository filling and sealing machines exclusively make suppositories that you administer to the urethra.

Rectal suppository filling and sealing machines only make suppositories that will go into the rectal organs.

When should you use AluAlu Suppository Machine?

Suppository processing machine

Suppository processing machine

An AluAlu suppository machine is suitable for suppositories that are extremely sensitive and hygroscopic.

Also, it will fill and seal light-sensitive suppositories with the AluAlu foils.

Which Technical Parameters should you Consider in Suppository Machines?

The technical parameters differ from one machine to the other, and they include:

  • Filling capacity of between 2500 and 15000 units per hour.
  • An accuracy of +/- 1.5%.
  • A voltage of 240V or 380 V, 50 Hz, and 4/5 KW.
  • Air consumption of between 0.3m3 and 1.0m3 per minute.
  • Average weight of between 400 kg and 6000 kg.
  • Filling dose of between 1 gm and 6 gm.
  • Bullet, duck, or torpedo suppository belts.

At SaintyCo, we design and manufacture high performance suppository machines depending on client’s needs.

Talk to us today for all your suppository filling and sealing machines.

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