Manual (300-1,000 caps/hr): Hand-operated, requires loading each capsule

Semi-auto (1,000-10,000 caps/hr): Machine fills but requires manual tray loading

Fully auto (30,000-200,000 caps/hr): Complete automation with minimal human intervention

Standard machines handle sizes 000 to 5. Or you can check our capsule size chart!

Powders (most common)

Granules/pellets

Micro-tablets

Liquids (with special attachments)

Semi-auto: ±3-5% variation

Fully auto (GMP): ±1-3% variation

Manual: $100-$500

Semi-auto: $1,000-$10,000

Fully auto: $20,000-$500,000+

Be cautious of “theoretical speeds” quoted by suppliers. These are often based on the smallest capsule sizes (e.g., Size 3 or 4).

• The Reality: If you are filling large capsules like Size 00 or 000, the actual stable output will likely be 10–20% lower due to the physical limitations of the mold cavities.

• Action: Ask the supplier to specify the “Stable Working Output” for your specific capsule size and material. Reputable suppliers will provide these realistic figures, for example, “150,000/hour theoretical, 125,000/hour stable for Size 00.”

Yes, absolutely. Insist on a Factory Acceptance Test.

• Process: Send a batch of your empty capsule shells and a few kilograms of your powder blend to the manufacturer.

• What to Verify:

  1. Fill Accuracy: Can the machine consistently achieve your target weight within the required tolerance (usually ±2% to 5% )?

  2. Yield/Reject Rate: What percentage of capsules are damaged or mis-filled? The industry standard is a reject rate of less than 1% .

  3. Material Handling: Observe how your powder flows through the machine. Does it bridge or clog in the hopper?

A reliable manufacturer will:

• Welcome you to visit their factory and meet the engineering team.

• Provide the machine’s unique serial number and QA logs.

• Have engineers available to answer detailed technical questions about mechanical design or software logic, not just salespeople.

• Offer a transparent spare parts list with pricing upfront, allowing you to estimate your total cost of ownership for the next 2–3 years.

Standard operating procedure involves three key checks:

1. Environmental Check: Ensure the room temperature is 18–26°C (64–79°F) and humidity is 45–65% RH. Incorrect humidity makes capsules brittle (too dry) or sticky (too humid).

2. Material Handling: Pre-sieve your powder through an 80–100 mesh screen to break up agglomerates. Crucially, know the bulk density of your powder—this is the primary data point for calibrating the filling weight.

3. Machine Check: Verify compressed air pressure (0.4–0.6 MPa / 58–87 PSI), power supply, and that all safety guards and emergency stops are functional.

 Powders with a high angle of repose (>40°) or that are sticky can cause inconsistent filling. Solutions include:

• Formulation Adjustments: Add glidants like fumed silica or magnesium stearate to improve flow. Granulating the powder (creating larger, denser particles) is the most effective solution.

• Machine Adjustments:

  • For very “floodable” powders that flow like water, you may need a compression screw (smaller pitch) to prevent the material from leaking out of the dosing chamber uncontrollably.

  • Ensure the agitator forks or paddles inside the hopper are working correctly to prevent bridging.

 Inconsistent fill weight is the most common issue. Troubleshoot in this order:

1. Powder Condition: Check for segregation, clumps, or changes in moisture content in the hopper.

2. Dosing System: For dosator machines, check if powder is sticking to the tips of the filling pistons (“picking”). For tamping machines, check if the tamping pins are worn or if the holes in the dosing disc are clogged.

3. Mechanical Wear: Inspect the dosing disc or pistons for wear. Worn components cannot create a consistent vacuum or compression, leading to weight variation.