The efficiency and precision of capsule filling is critical in The Pharmaceutical Industry. There are semi-automatic capsule machines and automatic one, each of them has its own pros and features for operation. Knowing the difference in these two machine types can help guide manufactures into what may be best based on their production needs and budget or just level of automation.
Operational Speed and Volume
One of the fundamental contrasts between half auto and completely automatic container packaging machinery is their operation speed and yield limit. Fully automatic machines are built for high volume production environments where speed is of the essence. These machines run the full range of 150,000 up to as many as 250,000 capsules per hour depending on model and parameters. On the other hand, semi automatic capsule machine can typically manufacture between 25,000 to 50,000 capsules per hour. Medium output allows their usage for other levels such as Medium scale operations or speciality pharmaceutical products.
Involvement of the operator and cost of Labor
Fully automatic capsule machines need less operator interaction, and hence labor cost is lower and the chances of human error are dealt with. From sorting empty capsules to filling and sealing them, these machines take care of everything required in the capsule-filling process right until the end product comes spitting out. Semi-automatic: These machines are manual and require a person to load capsule bodies, caps into the machine before filling. This higher level of operator intervention requires more manpower and training but allows for greater influence in terms of what is involved with the filling process.
Flexibility and Setup Time
Changeover between different capsule sizes or products is easier on semi-automatic machines. They generally feature faster setup times due to their reduced number of mechanical and electronic adjustments. Manufacturers producing a many different capsule designs or multiple products use this versatility to their advantage. Fully automatic machines although capable of great speed, typically require longer times for setup once the tablet size or product is changed due to a number of mechanical parts that must be adjusted along with control settings;
Investment and Maintenance Costs.
A completely automatic capsule machine requires a considerable amount of initial investment when compared to semi-automatic machines. Fully automatic-beans-to-glass machines should be marketed as luxury items since the advanced technology and components they use cost more to build. Also, the cost of maintaining those machines can be higher because such a way advanced systems doing things that only ever call for troubleshooting by highly qualified specialists. Rest easy though, because semi-automatic machines are simpler in build and contain fewer electronic working parts so they generally have lower maintenance costs when compared to fully automatic machines.
Accuracy and Waste Reduction
Even though both types of machines have high accurate with regards to capsule filling, fully automatic ones are planned in a way that can utilize the material and minimizes waste. They are fitted with precision control systems which continuously monitor fill weights, and reject capsules outside a predefined band. Since we can manage the TDS, it means that there will be little to no material waste as well for quality control is maintained from batch to batch. Though the semi-automatic machines are very accurate, there is likely some increased variability due to human filing.
Final Thoughts
When it comes to semi-automatic vs fully automatic capsule machine, factors like production volume,budget,operational flexibility and labor cost will be considered. If you are in large scale high volume production at least labor as possible a fully automatic machine is your best bet. But for smaller operations or where they need to change their product frequently, a semi-automatic machine does give the flexibility and is more economical investment wise. For a pharmaceutical manufacture who is looking to make improvements in their own production process - as well more generally ensuring that they are able to maintain high levels of quality and efficiency, the differences between these machines need full understanding.