250-II Softgel Encapsulation Machine

The doubled production capacity results from patented spray body and feed system technology that optimizes fill material distribution across all fill stations. Conventional softgel encapsulation machines with 250 mm die width typically operate at 4–5 rpm maximum speed due to material feeding limitations. This machine's advanced feed system enables reliable operation up to 10 rpm while maintaining fill accuracy, effectively doubling throughput without increasing the machine's physical footprint or requiring wider die tooling. This means manufacturers can achieve production rates previously requiring larger-format machines while retaining compatibility with existing 250 mm tooling inventories.

Mechanical softgel encapsulation machines use a geared transmission system to synchronize all machine functions, providing proven reliability with well-understood maintenance requirements. Servo-driven machines replace mechanical transmissions with independent servo motors for each axis, enabling features like automatic die alignment and automatic thickness adjustment. This mechanical high-capacity model delivers equivalent production throughput (up to 241,920 capsules/hour) at a lower investment cost, making it ideal for manufacturers prioritizing maximum capacity per dollar invested. Servo models offer additional automation features that reduce setup time and changeover labor, which is more valuable for facilities running many different products.

Yes, the patented feed system technology is available as an upgrade package for compatible existing softgel production equipment. This upgrade path enables manufacturers to substantially increase production capacity without full machine replacement, significantly reducing capital expenditure and minimizing production downtime during implementation. The feasibility of upgrading depends on the specific make and model of the existing equipment; our engineering team can assess compatibility and provide detailed upgrade proposals based on your current equipment specifications.

The machine has a theoretical maximum output of 241,920 capsules per hour for size 8 Oval capsules at 8 rpm operating speed. In typical pharmaceutical and nutraceutical production environments, sustained output ranges from 70–85% of theoretical capacity, depending on formulation characteristics, operator efficiency, planned quality checks, and material change intervals. This translates to approximately 170,000–205,000 capsules per hour in real production conditions, which remains substantially higher than standard mechanical machines of equivalent die width.

Yes, this high-capacity rolling-mode softgel machine is designed with cGMP-compliant construction principles including pharmaceutical-grade stainless steel product-contact surfaces, sanitary design with smooth crevice-free finishes, and modular construction for cleanability. The PLC control system supports batch parameter documentation and recipe management. Comprehensive documentation packages are available to support IQ/OQ/PQ validation activities required for pharmaceutical facility qualification. The equipment is suitable for production facilities operating under FDA, EMA, or ASEAN GMP regulatory frameworks with appropriate site-specific qualification procedures and SOP development.

The mechanical drive system has well-established maintenance requirements including periodic lubrication checks, seal inspections, and bearing monitoring. The dedicated professional lubrication pump system for the transmission extends trouble-free operating intervals significantly compared to manually lubricated machines. Routine preventive maintenance is typically scheduled on a monthly or quarterly basis depending on operating hours. With proper preventive maintenance programs, these machines demonstrate high production uptime and reliable multi-shift operation capability, making them suitable for facilities running two or three production shifts daily.

Yes, the machine supports both traditional animal-based gelatin formulations and plant-based starch softgel production without requiring mechanical component changes or die reconfiguration. This dual-material capability allows manufacturers to produce both conventional and vegetarian softgel product lines on a single production platform, maximizing equipment utilization and reducing capital requirements for facilities serving both market segments. Process parameters for different shell materials are stored as recipes in the control system for quick recall during product changeovers.

The machine has overall dimensions of 2,200 mm × 1,000 mm × 2,100 mm (length × width × height) and requires 12 kW of installed electrical power. The system also requires connection to an external recirculating chiller for gelatin roller temperature control. Standard compressed air supply is required for pneumatic control functions. For cleanroom installation, the machine's enclosed frame design and smooth exterior surfaces facilitate integration into Class D or equivalent cleanroom environments. Detailed facility requirement specifications including utility connections, floor loading, and clearance requirements are provided during quotation.

The four independent micro-lubrication pumps deliver precisely controlled lubricant volumes to each gelatin roller surface, ensuring uniform oil film distribution across the entire roller width. Excessive lubrication causes oil carryover onto capsules, requiring additional cleaning steps and potentially affecting capsule surface quality. Insufficient lubrication causes capsule sticking and die release problems. The digital control system with recipe memory ensures consistent, optimal lubrication for each formulation, eliminating the need for post-encapsulation capsule washing and reducing drying time because excess lubricant does not need to evaporate. This improves both product quality and overall production line efficiency.

The machine is compatible with a broad range of liquid and semi-solid fill materials appropriate for rotary die encapsulation, including pure oils, oil-based suspensions, lipid formulations, vitamin concentrates, herbal extracts, fish oil, self-emulsifying drug delivery systems (SEDDS), and traditional Chinese medicine active compounds. The system handles fill materials with viscosities within the standard range for softgel encapsulation processes. For novel formulations or materials with unusual properties, we recommend laboratory-scale trial runs to confirm optimal machine settings and production feasibility before committing to full-scale production equipment.