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    Capsule Filling
    Capsule Filling

     

     

    Capsule filling machine

    Syntegon capsule filler

    Our automatic capsule filling machine series provide best conditions for highest pharmaceutical standards – from R&D and pilot scale to high production volumes. Whether you need to fill powders, (mini-) tablets, pellets, granules, liquids, or different combinations into hard shell capsules (HPMC or gelatin capsules), we offer you the appropriate process technology for the production of both pharmaceutical and health and nutrition products (supplements). We also provide a containment concept for several capsule filling machine platforms for the production of potent APIs up to OEB 4 or OEB 5, which ensure the highest operator protection.

    Capsule filling applications

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    Powders/pellets

    Dosing station with optimized slide-gate technology for the filling of powders, granules, and pellets.

    syntegon-capsule-pellets
    Pellets

    The pellet station is a gentle, precise, and compact option for the volumetric dosing of pellets with different characteristics.

    syntegon-capsule-tablets
    (Micro-) tablets

    The tablet station doses single and multiple tablets into capsules gently and precisely – from big oblong to micro-tablets.

    syntegon-capsule-micro
    Vacuum-wheel dosing

    Vacuum-wheel dosing is especially suited for dry powder inhalation (DPI) and active pharmaceutical ingredient (API) dosing with a high accuracy for small quantities.

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    Liquids

    The liquid station enables the precise volumetric dosing of hydrophilic to thixotropic liquids. It can also heat liquids for optimum viscosity during the filling process.

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    Combinations

    The GKF series can fill a wide array of product combinations thanks to its modular assembly. Various successful projects underline our expertise.

    Why choose a Syntegon capsule filler?

    capsule-filling-machine

    Capsule filling machine manufacturer

    Syntegon is your reliable partner for process technology in the global pharmaceutical industry. We offer you solutions for all requirements – from R&D and pilot scale to high volume production, based on more than 50 years of experience as a capsule filling machine manufacturer.

    • Capsule fillers for powder, pellets, (micro-) tablets, liquids, and combinations
    • Quality control during manufacturing through NWDS capacitive sensor
    • PAT Classic for detailed insights into critical process parameters
    • Counting systems for tablet filling
    • Modular and flexible machine design
    • Integrated IPC control system (gravimetrical scale)
    • Automatic high-precision capsule checkweighing
    • Various operator protection concepts (containment up to OEB5)

    Our capsule filling machines

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    Our capsule filler machine portfolio at a glance

    automatic-capsule-filler-Syntegon-GKF-2600

    GKF Performance series

    The future-proof GKF Performance series features highly flexible capsule filler machine platforms that ensure the highest pharmaceutical production standards. Based on more than 50 years of experience as a capsule filling machine manufacturer, the machines are designed to facilitate complex dosing processes and are equipped with fully integrated inspection technologies. The GKF Performance series is capable of filling different types of products or combinations into hard shell capsules (HPMC or gelatin capsules). All capsule fillers of the Performance series are also available with the Syntegon ProTect and HiProTect containment concept for highest operator protection.

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    capsule-filler-GKF-1400

    GKF Selection series

    The GKF Selection series provides best conditions for modern, flexible, and safe capsule filler operations. All machines are capable of filling different types of products or combinations into hard shell capsules (HPMC or gelatin capsules). Thanks to their modular assembly, the capsule fillers can accommodate applications for (mini-) tablets, pellets, granules, liquids, or combinations. Quick changeover times and intuitive handling make the GKF Selection series your ideal choice for the production of both pharmaceutical and health and nutrition products (supplements).

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    capsule-filling-machine-Syntegon-GKF-720

    GKF Containment series

    Containment is all about operator safety. The product area is separated from the personnel area by a barrier system to prevent any negative impacts (contamination). Syntegon provides two different solutions for OSD (Oral Solid Dosage) processing under containment conditions: the ProTect (up to OEB 4) and HiProTect (up to OEB 5) execution. We further offer three different cleaning approaches for closed capsule filler machines, which you can adapt to your specific needs together with our experts.

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    capsule-filling-Syntegon-GKF-capsylon-1505

    GKF Capsylon series

    The GKF Capsylon machine series is specially designed for the nutrition and health industry (supplements). It provides the renowned Syntegon quality at an excellent price-performance ratio. The capsule fillers are suited for the filling of powders, pellets and granules into various capsule sizes. They meet the growing need for high efficiency, easy operation, and simple cleaning. The GKF Capsylon machine series is the ideal solution to increase your production capacity while reducing unit dosage costs.

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    Service Agreements
    Service Agreements

    Find out more about our Service Agreements here.

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    Digital Solutions
    Digital Solutions

    Find out more about Digital Solutions here.

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    Maintenance
    Maintenance

    Find out more about Maintenance here.

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    Technical Support
    Technical Support

    Find out more about Technical Support here.

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    Modernizations
    Modernizations

    Find out more about Modernizations here.

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    Training
    Training

    Find out more about our Training here.

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    Expert Services
    Expert Services

    Find out more about our Expert Services here.

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    Downloads

    Pharma Solid overview brochure
    Pharma Solid overview brochure

    Discover our solutions for mixing, drying, granulating, coating, capsule filling, and tablet pressing.

    Download
    R&D Equipment
    R&D Equipment

    Our R&D equipments

    Download
    Automated Process Development (APD)
    Automated Process Development (APD)

    A sophisticated approach to laboratory automation.

    Download

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    FAQs on capsule filling

    Syntegon’s in-house OSD Customer Center provides the entire processing infrastructure, from clean room facilities to equipment for processing trials. The Customer can perform the trial themselves or have the Syntegon process specialists perform the trials for them. Customers can bring their own capsules or use empty capsules provided by Syntegon for the machine trials. 

    The capsule filling process on our GKF capsule fillers involves several steps

    1. Capsule alignment and separation: After loading of the empty capsules into the segment of the GKF capsule filler, the capsules are aligned and separated.
    2. Upper/lower segment separation: The empty capsules will be separated into two parts – the upper part and the lower part (capsule cap and body respectively), which are filled with the product at the dosing station.
    3. Ejection of non-separated capsules: In this station all empty capsules that have not been separated earlier in the process, are removed.
    4. Dosing station for powder or pellets: The lower part of the empty capsule is filled with the Customer’s product (powder, pellets, tablets or liquids).
    5. Segment alignment: This station ensures the correct alignment of the upper and lower capsule parts in order to achieve a secure seal.
    6. Capsule closing station: The upper part of the capsule is sealed together with the lower part which has been filled with the Customer’s product (powder, pellets, tablets or liquids).
    7. Ejection of filled capsules: After the capsule closing station, the GKF capsule filler identifies the successfully sealed capsules and removes them from the machine.
    8. Segment cleaning station: In the last station of the capsule filling process, the capsule segments are cleaned to ensure that empty capsules can be loaded for rhe next filling cycle. 
    According to the Customer’s preferences and the specification of the GKF capsule filler, additional stations can be added. In addition, several quality control and inspection technologies are offered for better process monitoring and assurance.
    All types of empty capsules can be filled on the GKF capsule filler. The two main types are gelatin capsules and hydroxypropylmethylcellulose (HPMC) capsules. The HPMC capsules offer a vegan alternative to the gelatin capsules.

     

    Different types of components and component combinations can be dosed on our GKF capsule filling machines:
     
    Powder: Dosing station with optimized slide-gate technology for the filling of powders, granules, and pellets.
     
    Pellets: The pellet station is a gentle, precise, and compact option for the volumetric dosing of pellets with different characteristics.
     
    (Micro) Tablets: The tablet station doses single and multiple tablets into capsules gently and precisely – from large oblong to micro-tablets.
     
    Micro-Dosing: Vacuum-wheel dosing is especially suited for dry powder inhalation (DPI) and active pharmaceutical ingredient (API) dosing with a high accuracy for small quantities.
     
    Liquids: The liquid station enables the precise volumetric dosing of hydrophilic to thixotropic liquids. It can also heat liquids for optimum viscosity during the filling process.
     
    Combinations: The GKF series can fill a wide array of product combinations thanks to its modular assembly. Various successful projects underline our expertise.
     
    Specials: Capsule into capsule. 

    We offer a range of inspection technologies in our portfolio to meet your needs. Our portfolio of inspections technologies include:
     
    KKE series: The KKE capsule checkweighing series sets the standard in 100 % capsule weighing. With its mechanical pre-dedusting system, the precise gravimetric weighing technology makes the KKE series the ideal choice for your capsule checkweighing needs. The platforms also answer the growing needs of the nutraceutical and health industry (supplements) in terms of process control and increases product quality in your capsule production. Need more information? Learn more about our KKE series here.
     
    In-process control: The integrated gravimetric scale system ensures an automatic statistical capsule check weighing for low fill-weight capsules. It allows the Customer to analyze those capsules in real-time, improving quality and reducing waste.
     
    Net-weight-detection system (NWDS): 100% net weight control system with  weight determination via electromagnetic field sensor. During the dosing process, the dosing mass passes through a mass detection sensor. Here, the interruption generated in the sensor field is measured against a pre-set mass to weight reference that is set during an automated teach in process with the integrated IPC.
     
    Process optimization technologies: 

    • PAT Classic (Process Analytical Technologies): The PAT Classic system offers powder height detection, ejection force detection and closing force detection. It supports operators in running a stable capsule filling process, its also avoids dosing errors and product loss. Furthermore, it can prevent machine damages and increases the overall yield.
    • APD (Automated Process Development): Automated process development (APD) is a sophisticated approach for fast and efficient process development for new formulations and optimization of existing products. Combining systematic planning (DoE = Design of Experiments) with a patented automated execution set-up on a capsule machine, APD is a unique methodology which enables the performance of a higher number of experiments in a shorter time with reduced product consumption.
    • ASB Function: The integrated automated troubleshooting function ensures maximum productivity and quality. It automatically corrects malfunctions in the capsule handling process, resulting in less machine downtime.
    • Single Capsule Rejection: Non-separated capsules are automatically rejected during the capsule filling process.
    • No Cap No Fill: If a defined number of caps are missing the no cap no fill function switches off the subsequent dosing stations. Un-filled capsules are then ejected at the cleaning station. No Cap No Fill improves yield and reduces product loss. 
       

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    Interested in a capsule filling machine?

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