How To Adjust The Filling Volume of A Automatic Capsule Filling Machine

Adjusting the dose of a fully automatic capsule filling machine requires precision and careful operation. Below is a detailed step-by-step guide and key considerations:

I. Preparation

1. Check Machine Status

• Ensure the machine is powered off and in a stopped state.

• Clean critical components (e.g., molds, filling rods, dosing discs) to avoid residual powder affecting accuracy.

2. Prepare Tools

• Electronic balance (accuracy ≥ 0.01g), measuring tools, calibration weights.

• Empty capsules (matching production specifications) and filling material (must meet process requirements, e.g., particle size, flowability).

3. Material Testing

• Check bulk density and flowability; pre-process if necessary (e.g., sieving, drying).

II. Steps to Adjust Filling dose

1. Adjust Filling Rod Height (Coarse Adjustment)

• Principle: The depth of the filling rod determines the filling dose—deeper insertion increases weight.

• Operation:

• Clockwise: Rod moves downward → Increase filling volume.

• Counterclockwise: Rod moves upward → Decrease filling dose.

1. Locate the adjustment screw or handle (position varies by model; refer to the manual).

2. Loosen the locking nut and rotate the screw:

3. Tighten the nut after initial adjustment and test manually (do not power on).

2. Adjust Dosing Disc Thickness (Fine Adjustment)

• Applicability: Used when rod adjustment is insufficient or dose variation is large.

• Operation:

1. Remove the dosing disc and replace shims (typically 0.1mm, 0.2mm, etc.).

2. Thicker shims → Larger filling space → Increase volume; thinner shims reduce weight.

3. Adjust Filling Speed (Auxiliary Adjustment)

• Some models allow speed or vibration frequency adjustments (low speed for poor-flow materials).

4. Test Run & Weighing

1. Manually fill 10–20 capsules and weigh each.

2. Calculate average weight. If outside target:

• Underweight: Slightly lower the rod or add shim thickness.

• Overweight: Adjust inversely.

3. Repeat until weight stabilizes within ±5% of target (e.g., 285–315mg for 300mg target).

III. Key Considerations

1. Material Properties

• Poor-flow powders (e.g., fine herbal powder) may require vibration assistance or forced-feeding mechanisms.

• Segregation-prone blends (e.g., granules + powder) need optimized mixing.

2. Machine Calibration

• Regularly calibrate the balance with standard weights.

• Check filling rod wear; replace if severely worn.

3. Process Validation

• After 30 minutes of continuous operation, sample again (typically 20 capsules) to confirm stability.

• Record adjustment parameters (e.g., rod height, shim thickness) for future reference.

4. Regulatory Compliance

• Follow pharmacopoeia (e.g., USP/ChP) or GMP standards for weight variation (e.g., ±10% for ≤0.3g average weight).

IV. Troubleshooting

• Unstable Weight: Check for material clumping, loose molds, or air pressure fluctuations (pneumatic models).

• Capsule Damage: Excessive rod pressure or mismatched capsule size.

• High Variability: Material segregation—optimize mixing or add flow aids.

V. Safety Notes

• Always power off before adjustments to avoid pinch injuries.

• Wear dust masks, especially for toxic or irritant powders.

By systematically following these steps, capsule filling volume can meet specifications. If issues persist, consult the Migrand’s technical support.

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