How to Troubleshoot and Maintain Your Manual Capsule Fillers？

As the most commonly used filling machines, manual capsule fillers are easy to use and low-cost.  Operators simply need to place the empty capsules caps and bodies into the plates, then add powder into the bodies. Once filling is complete, the cap plate is placed over the body plate for pressing. Through repeated pressing, capsule caps and bodies can stick tightly. Finally, separate plates to get filled capsules. The whole process is finished only by human effort. So they are more suitable for small to medium-scale production and newbies in pharma manufacturers.

However, manual capsule filling machines can meet various issues because of human effort. They may impact product quality and production efficiency. Here are some problems you may meet.

Inconsistent Capsule Weight

Inconsistent capsule weights are a common issue during the manual capsule filling process. It is mainly caused by incorrect powder density and filling techniques. When the powder density is too high or too low, the filled capsules may be overweight or underweight. Additionally, the operator's filling method can affect the weight of each capsule, especially when compacting the powder. Improper techniques can lead to uneven dosing. To address this issue, operators need to have some experience and master essential filling skills. Moreover, you can use an electronic scale to measure the powder for each. It ensures that each capsule has a consistent weight.

Powder Spillage

This problem often occurs due to overfilling. It adds too much powder, causing overflowing. Improper filling will also cause it. It may be because operators don’t level off the excess powder after filling each capsule. When operators rush the process, spills can easily happen, leading to waste and mess.

Therefore, careful filling practices are essential. After filling, operators should use a spreader to clean the extra powder. It ensures every capsule contains the same volume of medicine. It is also crucial to maintain a clean work area. You’d better clean the device regularly to help remove any residual powder. This not only prevents inaccuracies in dosages but also minimizes the risk of overflow. Meanwhile, it helps avoid cross-contamination between different medications.

Difficulty in Capsule Sealing

Sealing capsules can be difficult due to various factors. One major issue is moisture content. High moisture can cause the powder to become sticky. This prevents proper sealing of the capsule halves. Poor-quality capsules may also lead to sealing problems. If the capsules do not fit together well, it can result in gaps that allow air to enter. Another factor is the pressure used during the sealing process. If the pressure applied is not even or sufficient, the capsules may not seal tightly.

For moisture content, you need to control humidity levels in the workspace. A dry environment helps maintain the right moisture content in the powders. In addition, you should apply consistent pressure to compress the filled capsules tightly. If your operators are not experienced, training is a must.

Jamming or Misalignment

Manual capsule fillers are always made of acrylic. Issues like jamming can occur because of improper operation. If the two sheets are not properly aligned during sealing. It may cause capsules to mismatch. So before each use, you’d better check the alignment of the plates for smooth operation. In addition, regular maintenance is key. It ensures the components remain free of powder residue. Nowadays, many manufacturers choose the powder guard with a U-shape. It minimizes powder loss for more even filling.

Issues with the Device

Aside from improper manual operation, the machine itself may also experience issues that lead to filling failures. Here are several common causes and solutions for your reference.

How to Maintain Manual Capsule Filler?

To keep a manual capsule filler in great shape, it's essential to focus on regular cleaning and lubrication. You should use a nylon brush or air pump to remove any residue. Also, it is a good idea to clean with room-temperature water to prevent damage. If there are hard-to-reach areas, a toothbrush can be a good helper. Please note that you should avoid soaking the machine in harsh liquids like alcohol.

After cleaning, apply a food-grade lubricant to the cam and its moving parts. It improves the operation process. It's best to do this maintenance at the end of each day or shift, regardless of whether you plan to use the machine again soon. This routine not only helps prevent clogs or stickiness but can also significantly extend the machine's lifespan.

Partner with iPharMachine for High-Quality Manual Capsule Fillers

As a leading equipment supplier in China, iPharmahcine offers various types of capsule fillers, including manual models. If you need semi-automatic or fully automatic capsule filling machines, it is also ok. You just need to tell us your capsule types and applications, we can select the most suitable one for your business. If you worry about how to operate the machine well, we also have a professional technical team for training. If you have any questions, feel free to contact us.