Capsule filling machine – GKF Containment

GKF capsule filling containment solutions

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 filling machines, which you can adapt to your specific needs together with our experts.

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Key benefits

Fully automated processes

Operator intervention is reduced and protection increased thanks to automated capsule filling

Profound expertise

Our containment expert team will be happy to consult you in implementing your ideal containment solution

Cleaning solutions

We have the right cleaning concept for your containment application – from entry-level dry cleaning to automatic Washing-In-Place (WIP)

GKF 60 ProTect and HiProTect

R&D capsule filling machine – takes your molecule to production, even under OEB 4 or OEB 5 containment classifications.

GKF 720 ProTect and HiProTect

Provides an open and variable OEB 4 or OEB 5 platform with various features and filling stations.

GKF 1700 HiProTect

Unique containment solution that fills highly potent substances (OEB 5) and comes with an automated cleaning system.

GKF 2600 ProTect

Dry containment solution for potent pharmaceuticals up to OEB 4.

GKF 60 ProTect and HiProTect

The GKF 60, which achieves an output of up to 3,600 capsules per hour is available either in the ProTect execution based on a dedicated R&D laminar flow principle, or in the HiProTect execution with a closed door concept and glove port access. We further offer a combination of the manual dry and wet cleaning principle, or a WIP process with integrated spray nozzles.

GKF 720 ProTect and HiProTect

The GKF 720 ProTect and HiProTect provide all features and benefits of a flexible small batch production machine with outputs of between 3,000 and 43,500 capsules per hour. The capsule filling machines are equipped with an inflatable door seal, dedicated air handling, a filter concept and glove access. Cleaning can be done either with a combination of manual dry and wet cleaning or with a manual WIP process.

GKF 1700 HiProTect

The GKF 1700 HiProTect is a true containment machine, providing additional safety thanks to an own pressure zone concept. While achieving an output of up to 100,000 capsules per hour, the machine features a range of automated processes. A programmable washing system stores and recalls cleaning protocols, ensuring a reproducible cleaning result for your individual WIP process.

GKF 2600 ProTect

The GKF 2600 ProTect is ideal for a flexible product set-up and large batch production of up to 156,000 capsules per hour. It provides a dry containment solution with manual dry containment via integrated suction nozzle and an optional wetting process. It monitors negative pressure inside the production chamber and provides glove port access and an RTP option.

Our ProTect and HiProTect concepts at a glance

ProTect: Capsule filling machines in the ProTect execution can handle production processes that are classified up to OEB 4. The term „ProTect“ stands for a dry cleaning approach, with optional wetting system to reduce airborne contamination.

HiProTect: This machine series is suited for products requiring a containment classification up to OEB 5. All machines are available with a manual or automated WIP (Washing-In-Place) cleaning process.

Inspection technology under containment conditions

Integrated washable in-process controll (IPC) for statistical net and gross weight determination
Integrated and washable 100 % net weight detection system (NWDS)
Connected containment capsule checkweigher KKE with optional WIP approach

Operator interventions should be kept to a minimum when processing products on containment machines. Several automated features support the capsule filling process and the operators’ safety:

ASB function: automated troubleshooting system for blocked capsules
Automated feedback-loop from inspection technology to dosing system for self-adjustment
PAT features such as closing and transfer force, powder bed height adjustment
No-cap-no-fill function for improved yield and reduced product loss

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Technical data overview

	GKF 60 ProTect & HiProTect	GKF 720 ProTect & HiProTect	GKF 1700 HiProTect	GKF 2600 ProTect
Output	3,600 caps/h	3,000 up to 43,500 caps/h	100,000 caps/h	156,600 caps/h
Segment bores	1	5	12	18
Machine cycles	Max. 60 cycles/min	Max. 145 cycles/min	Max. 140 cycles/min	Max. 145 cycles/min
Dimensions (HxWxD)	1,900 x 1,000 x 900 mm	3,490 x 3,133 x 2,101 mm	2,044 x 2,036 x 2,390 mm	3,548 x 3,178 x 2,436 mm
Connected voltage	According to customer specification	380-480 V, 50/60 Hz Special voltages on request	400 V ±10% , 50/60 Hz Special voltages on request	380 – 480 V, 50/60 Hz Special voltages on request

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About us

Processing and packaging for a better life – this is what our employees work for every day. Looking back on a 160 years of experience, the portfolio of intelligent, innovative and reliable solutions help our customers in the global pharmaceutical and food industries to improve people‘s life.
With 1,100 service experts and a comprehensive service portfolio throughout the entire machine lifecycle from spare parts management to digital line optimization, Syntegon lays the foundation for smooth production processes for all customers.

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Why capsule sealing?

Capsule sealing with banding technology ensures the highest product quality and prevents liquid-filled capsules from leakage. Banding also provides an additional measure for anti-counterfeiting of capsules filled with powder or other components. Sealing provides an enhanced safety measure to meet regulatory requirements. Our Syntegon GKB 2100 banding machine can handle both hard gelatine and HPMC (plant-based) capsules.

The Syntegon GKB 2100 banding machine

The new GKB 2100 features a particularly robust and flexible process, combined with the highest yield and maximum process stability. The focus is on user-friendliness, as well as very good accessibility for cleaning and easy format part changeovers. Our banding machine achieves an output of up to 125,000 capsules per hour.