ZD-I Automatic Suppository Shell Making Machine
ZD-I Automatic Suppository Shell Making Machine
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.
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 Specifications||ZD-I|
|Central distance:||bullet head (torpeto) 17.5mm, duck mouth: 26.25mm|
|Suppository shape:||optional specification, shape. Design and machining according to user’s need|
|Application piece material:||PVC, PVC/PE height :60mm- 64mm thickness: 0.15±0.01|
|Overall dimensions||2100 * 700 * 1300 mm (L * W * H)|
|Weight of overall machine||500Kg|
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?
- What is a Suppository Filling and Sealing Machine?
- Which Industries use Suppository Machine?
- What are the Benefits of Suppository Forming and Filling Machine?
- Is there difference between Suppository Machine and Tube Filler Machines?
- How do you Choose Suppository Molds?
- How do you Increase Efficiency Suppository Filler?
- Are there Limitations of Suppository Machine?
- What are the Component of Suppository Machine?
- How does Suppository Machine Work?
- What Types of Suppository Machines are there?
- Which Factors should you Consider when Choosing Suppository Machine?
- What are the Quality Standards of Suppository Machine?
- What are the Advantages of Suppository Drug?
- Are there Disadvantages of Suppository Drug?
- Which Types of Suppository Bases can Suppository Machine use?
- What are the Various Methods of Manufacturing Suppositories?
- How can you Troubleshoot Suppository Machine?
- How do yo
- How much do Suppository Machine Cost?
- Is there a difference between Urethral and Rectal Suppository Filling and Sealing Machine?
- When should you use AluAlu Suppository Machine?
- Which Technical Parameters should you Consider in Suppository Machines?
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.
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:
- Polyvinyl chloride [PVC]
- A combination of Polyvinyl chloride [PVC] and Polyvinylidene chloride [PVDC], or
- 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.
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.
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:
- Cleansing properties
- Moisturizing capabilities
- Providing a freshening effect
- Preventing constipation
These industries use a suppository machine as the products they make will have a health benefit to consumers.
Such suppositories contain:
- Nutritional value
- Herbal benefits
What are the Benefits of Suppository Forming and Filling 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:
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.
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.
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.
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 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:
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.
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.
Choose a suppository mold that are compatible and that the physicians may prefer.
Ensure the mold:
- Works with the base you are using.
- Considers patients with sensitivities
- Meet various doctors requests
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.
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.
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.
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.
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.
There are many suppository machine variations available, and this can confuse one when selecting a machine.
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.
Manual suppository machines have a low production capacity than automatic suppository machines.
Fully automatic suppository machines require minimal to no skill by the operator.
This makes the operators easily replaceable.
Suppository machines are advancing as technology advances.
This makes operators redundant as the machines employ machine learning hence require less monitoring.
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:
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.
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:
- Blowing molds
- Heating molds, or
- 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:
- Material capacity holder
- Filling pump
- Circulating pump
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:
- Cooling tunnels
- Cooling fans
- Water chillers
This chamber will place additional heat on the ends of the suppositories.
A pneumatic sealing component will apply heat to seal the dosages.
After filling and sealing, the suppository packages pass via a cutting system.
It cuts the dosages in the right sizes.
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.
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:
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.
An unwinding clamp will transfer the film strip to the shell formation stage
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.
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 blades will slice the shapes of the suppositories to the precise shapes.
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.
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:
- Maintaining vaginal moisture and pH levels.
- Healing fungal infections
- 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:
- Cure anal pruritus and hemorrhoids
- Eliminate constipation
- 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:
The amount you have will influence the suppository machine you can purchase.
Always purchase a suppository machine that will meet all your production needs.
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.
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.
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
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
- Semi-synthetic fatty acid glycerides
- Synthetic fatty acid glycerides
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
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.