Pharmaceutical Capsule Manufacturing Systems by LOCUS PHARM
From R&D to Mass Production: Scalable Solutions for Every Output Need.
LOCUS PHARM engineers GMP-compliant capsule manufacturing lines for hard gelatin capsules (powders/pellets) and softgel capsules (liquids/suspensions). Serving pharmaceutical, nutraceutical, and cosmetic producers across emerging markets.
Machine Class Comparison:
| Type | Throughput | Automation | GMP Compliance | Ideal For |
|---|---|---|---|---|
| Benchtop Manual | 500-3,000 cph | Operator-filled | Basic | Startups, R&D |
| Semi-Auto | 3,000-20,000 cph | Partial automation | ISO 9001 | Small-batch production |
| Automatic | 20,000-80,000 cph | Full auto dosing | EU GMP Annex 1 | Medium-volume pharma |
| High-Speed Auto | 80,000-150,000 cph | Robotic handling | FDA 21 CFR Part 11 | Mass production |
Precision Dosing Technology
Pharma-grade accuracy across formulations:
Powders: ±3% deviation (vs. industry ±5%)
Pellets: Gentle vibration-free handling
Liquids: Peristaltic pump filling (±1%)
Hybrids: Dual filling stations (powder + liquid)
Hard Gelatin Capsule Systems:
| Machine Type | Throughput | Automation | Capsule Sizes | Key Application |
|---|---|---|---|---|
| Manual Benchtop Fillers | 500-3,000 cph | Operator-driven | Single size | Pilot batches, R&D |
| Semi-Auto Floor Models | 3,000-20,000 cph | Format change | #00-#3 | Small-batch production |
| Automatic Rotary Fillers | 20,000-80,000 cph | Full auto | #000-#5 | Commercial pharmaceuticals |
| High-Speed Rotary | 80,000-150,000 cph | Robotic | #000-#5 | Mass-market nutraceuticals |
Technical Process Breakdown
Hard Capsule Filling Sequence (Semi-Auto):
1. Separation: Empty capsules split in format disc
2. Dosing: Powder/pellets filled via precision shoe
3. Joining: Capsule halves reunited under pressure
4. Ejection: Finished capsules discharged
Softgel Encapsulation Process:
1. Gel Mass Prep: Heating → Degassing → Filtration
2. Encapsulation: Dual-die rotary casting with liquid injection
3. *Washing: Ethanol rinse for surface lubrication
4. Drying: Multi-zone tumble drying (15-35% RH control)
5. Inspection: Vision systems for defects/seams
Auxiliary Equipment Suite Hard Capsule Post-Processing:
Capsule Format Flexibility
Process all standard sizes (00#-5#) and materials:
Gelatin: Bovine, porcine, HPMC
Vegetarian: Pullulan, starch-based
Specialty: Enteric, delayed-release
| Sector | Typical Output | Key Features |
|---|---|---|
| Pharmaceuticals | 50,000-150,000 cph | Serialization, 21 CFR Part 11 compliance |
| Nutraceuticals | 20,000-80,000 cph | Quick-change tooling, washdown design |
| Cosmetics | 5,000-30,000 cph | Luxury finishes, small-batch flexibility |
| Veterinary | 10,000-50,000 cph | Antibiotic-compatible materials, large capsule handling |
| Parameter | Semi-Auto | Automatic | High-Speed |
|---|---|---|---|
| Output | 3,000-20,000 cph | 20,000-80,000 cph | 80,000-150,000 cph |
| Capsule Sizes | 00#-3# | 00#-5# | 00#-5# |
| Dosing Accuracy | ±5% | ±3% | ±2% |
| Changeover Time | < 45 min | < 20 min | < 15 min |
| Power | 220V/50Hz | 220V-380V/50Hz | 380V-480V/60Hz |
Our GMP-compliant capsule fillers feature:
— 316L stainless steel contact surfaces.
— Closed-system containment (OEB 4/5 compatibility).
— Full audit trails per EU Annex 11.
— Change parts documentation kits.
1. Quality Control:
— Metal detectors
— Vision inspection (deformed capsules)
— Checkweighers (±10mg)
2. Traceability:
— RFID tagging
— Aggregation systems (bottle→case→pallet)
— Russia’s «Chestny ZNAK» compliance
3. Downstream Integration:
— Bottle filling stations
— Blister packaging lines
— Serialization modules
Softgel Line Critical Add-Ons:
Gelatin melting/reactor systems
Ethanol recovery units
Infrared dryers
Softgel printers
Size calibration towers
Complete softgel encapsulation systems include:
— Gel Mass Preparation: Reactors with temp control (±0.5°C), vacuum degassing
— Rotary Die Encapsulation: Servo-driven pumps, capsule ejection systems
— Post-Processing: Ethanol wash → Multi-zone drying → Optical inspection
— Packaging: Bottle filling, blistering, or bulk container systems
Softgel Capsule Lines:
Integrated softgel encapsulation systems:
Dosing: ±1% accuracy for oils/suspensions
Gelatin Handling: Automated mass preparation & feeding
Post-Processing: Ethanol wash, drying, polishing, inspection
Output: 50,000-300,000 capsules/hour
| Region | Hard Capsule Solutions | Softgel Adaptations |
|---|---|---|
| SE Asia | Humidity-controlled dedusting (80% RH) | Tropicalized drying tunnels |
| Africa | 100-500V voltage stabilizers | Diesel-powered gel melters |
| Latin America | Spanish/Portuguese HMI | ANVISA validation packages |
| Eastern Europe | CE-compliant safety interlocks | EU GMP documentation suites |
✅ GMP Compliance Guarantee
✅ 24/7 Multilingual Support
✅ 24-month performance guarantee
✅ Local technicians in 18 countries
Free line configuration for your products, throughput validation testing!
Contact Specialists for GMP:
Compliance Roadmap:
CE, EAC, ISO 9001 certifications.
GMP-ready: 316L SS contact parts, CIP/SIP capabilities.
