Have you ever heard of a machine that can lessen your workload by counting capsules? Yes, we are talking about Capsule Counting Machine which is used in pharmaceutical industries to count the number of capsules manufactured accurately.
These machines are essential as they can assist you in keeping the correct count of moisture-sensitive capsules.
In this guide, you will get all the information regarding the capsule counting machine, its types, working and benefits.
Without further ado, let’s explore all the aspects of a capsule counting machine below.
What Is A Capsule Counting Machine?
A capsule counting machine is used in the pharmaceutical, nutraceutical and health industries to count the number of capsules, tablets, lozenges and even candies precisely.
With these machines, you can ensure medication safety and production efficiency at an industrial level. The sterility of your capsules is preserved as the stainless steel parts of the machine are made of food-grade material.
They make your work easier by precisely counting the number of capsules manufactured in bulk quantities. It not only counts but can perform the filling, capping, sealing and labelling operations for you. This machine can also detect defective products while counting, which is then separated from the rest of the batch.
Types of Capsule Counting Machine
There are three types of capsule counting machines available on the market.
- Manual
- Semi-automatic
- Automatic
1. Manual Capsule Counting Machine
You can opt for manual capsule counting machines when producing a small batch of capsules. These machines come with a flat tray with holes. Then you can pour the capsules on the tray. After this, you need to shake the tray so that the capsules fit into the holes. When all the holes are filled, you can remove the remaining capsules from the tray.
Following are the certain drawbacks of using these machines:
- They slow down the speed of production.
- They can not count if the capsules are too big or too small.
- You have to buy different trays with different number of holes for changing the amount of product in each packaging.
2. Semi-Automatic Capsule Counting Machines
These machines provide a better capsule count than manual capsule counting machines. You can use these machines for small to medium scale production in industries. They provide an accurate count and efficient production.
Semi-auto machines work on a vibrating mechanism. You need to pour the capsules directly into the hopper, from where they are sent down the turntable. To prevent the overlapping and sticking of capsules, the turntable spins to rotate the capsules falling through guided rails. There is a sensor that counts the number of capsules accurately.
3. Automatic Capsule Counting Machine
This is an advanced technology for counting the products in industries correctly with high efficiency. You can use these for large-scale production processes as they require the least manpower. These machines ensure the consistent and secure packaging of your products.
Just like semi-automatic machines, you have to put the capsules in the hopper from where they are sent to the vibrating tracks. These tracks separate and align with the products properly. The automatic sensor will send the product to the discharge gate for packaging. Then, a conveyor belt carries the product forward for capping and labelling.
Working of a Capsule Counting Machine
The operation of a capsule counting machine is very simple and effortless. You can easily operate without any special training. However, you have to be careful not to compromise on the quality of the product.
Following are the steps for working on a capsule counting machine.
Setting of Machine
First of all, you have to adjust the settings of the machine according to your production process. Normally, the settings include fixing the number of capsules to be counted and adjusting the bottle filling head.
Loading of Capsules
In the next step, you have to load the hopper of the counting machine with enough number of capsules to be counted.
Vibratory Phase
After adjusting the settings and loading capsules, the machine is turned on. From this step, you do not have to do anything manually. When the machine is turned on, the vibratory motor will shake the vibratory trays. This shaking will cause the capsules to fall on the trays in a sequence.
Counting of Capsules
In capsule counting machines, some sensors are integrated for the purpose of capsule counting. The capsules that have felt a vibratory sensation in the vibration phase are then stored in the counting compartment. The sensors then detect and count the number of capsules in the compartment.
Filling of bottles
In the last step, the counted capsules are transferred to a sleeve hopper. Then the bottles or containers are filled with capsules.
Factors to Consider When Buying A Counting Line
Purchasing a counting line seems to be a simple and easy process. However, there are certain things which you should keep in mind before making a decision. These are as follows :
- Cost of the machine should be considered according to the production scale. You should see whether to buy a manual, semi or fully automated counting machine.
- It is important to check the compatibility of the machine with the product to be counted.
- You should evaluate your manufacturing needs as well before making a purchase of a counting machine.
- Choose a machine that is flexible enough for various dosage forms and their sizes. This will save a lot of time and cost at the end of the day.
- Install safety features such as interlocks and buttons to stop in case of any emergency.
- Make sure that your machine is energy efficient so that you can reduce the carbon footprint and ultimately protect the earth’s environment.
Benefits Of A Capsule Counting Machine
There are various benefits of investing in the right capsule counting machine. Some of them are as follows.
Accuracy
With these machines, you can reduce the chance of errors up to 90%. Manual counting can be difficult and leaves a doubt in mind. With automatic counting machines, you can easily count large quantities of capsules with accuracy in no time.
Saves time
The automatic counting machines save a lot of time by counting and packaging thousands of capsules in seconds.
Cost Efficient
You can minimize labor costs and material waste as these machines reduce errors and speed up the production process.
Productivity Enhancement
When counting is done effortlessly with these automatic machines,you can conveniently focus on other important tasks. Thus, it increases the overall productivity of operations.
Safety Precautions
You should always adopt certain safety precautions when operating with such equipments in industries. Some are as follows :
- Properly install machine for better working.
- Make sure that grounding for power supply is reliable. You should always cut off the main power supply when replacing or unplugging.
- Switch off the equipment and cut off the power supply when you start cleaning.
- You should never pull out the wires abruptly. Instead, pull out the plug head slowly and cautiously to protect the circuit from breaking.
Conclusion
The capsule counting machines have revolutionized the production processes in industries. They decreased the workload and enhanced productivity of businesses. The automated counting machines, in particular, provide the accurate count of capsules in a shorter time than manual or semi-automatic machines.
We at Sanity Co provide solutions to all your problems related to manufacturing of pharmaceutical machines, including capsule counting machine. You can leave a comment if you still have any questions regarding capsule counting machine.
FAQs
Do these machines need to be calibrated? How often?
Yes, in order to maintain precision, these machines need to be calibrated regularly. Frequency of calibration depends on usage and type of machine.
