Capsules are a widely used dosage form in the pharmaceutical and nutraceutical industries, offering precise dosing, ease of management, and improved patient compliance. Filling capsules with powder requires accuracy, efficiëntie, and adherence to good manufacturing practices, whether in large-scale production or small-batch compounding.
How to dispense powder to capsules? How to fill capsules in mass output? The methods employed vary significantly depending on the production volume, budget, and intended use, ranging from fully automatic capsule filling machines to hand-filling techniques.
Large pharmaceutical companies typically rely on high-speed, fully automatic capsule fillers which can produce hundreds of thousands of capsules within an hour. These machines, such as the Bosch GKF series or Ruida Packing NJP-5500D capsule filling models, integrate precise powder dosing, capsule sorting, vulling, and locking in a single streamlined process. They are ideal for mass production of commercial drugs, where consistency, snelheid, and regulatory compliance are critical.
On the other hand, semi automatic capsule filling machines, with outputs ranging from a few several thousand to tens of thousand capsules/hour, serve as a middle-ground solution for medium-sized manufacturers or specialized pharmacies that require flexibility without full automation.
In een ander aspect, a manual capsule filler or even handheld capsule filling tools are preferred by small-scale producers, compounding pharmacists and DIY enthusiasts. These methods are cost-effective and allow for customization in formulations, suitable for clinical trials and personalized medicine with low output demands.
1. How to Dispense Powder to Capsules by Using a Semi–Auto Capsule Filler?
A semi automatic capsule filling is a versatile device designed to make empty capsules filled with ingredients such as powders, granules or pellets. It combines manual and automated operations, making it ideal for medium-scale production. The CGNT-209 model, Bijvoorbeeld, is a popular semi-automatic capsule machine that ensures precision in capsule filling. A guide on how to operate this capsule making machine is shown below.
a semi-auto capsule filling machine
Stap 1: Feeding Materials
Eerst, pour empty capsules into the capsule feeding hopper and the medicinal powder (or granules/ pellets) into the drug feeding hopper. The machine will separate and align the capsules for further processing.
Stap 2: Installing the Capsule Filling Tray
Empty capsules are transferred via a capsule dispensing tubes onto capsule filling trays. Once trays are fully loaded, they rotate automatically to ensure proper separation of capsules— separating bodies from caps.
Stap 3: Filling Capsules
Move capsule filler trays to the capsule filling station. The equipment separates the upper and lower trays, exposing capsule bodies for ingredient filling. Powder is then dispensed into capsules automatically.
Stap 4: Powder Compression (Optioneel)
For better powder density, place a compression plate (tamping plate) with compression pins over the filled capsules. Press down the plate to compact the powder, then repeat the filling process to ensure complete dosage accuracy.
Stap 5: Capsule Locking
Transfer capsule trays to the capsule locking station. Press the start button, and the semi-auto capsule filler will automatically rejoin capsule caps with capsule bodies, locking them securely.
Stap 6: Collecting Finished Capsules
Once capsules are locked, the capsule filler machine will output filled capsules into a collection bin, ready for packaging or further processing.
Compared to a manual pill capsule filler, the CGNT-209 semi auto capsule filling machine simplifies the encapsulation process. By following these steps— material feeding, separating, vulling, compressing (if needed), locking, and collecting— users can more conveniently produce uniform capsules with minimal manual intervention. This machine is an ideal option for pharmacies, labs and small manufacturers.
2. How to Dispense Powder to Capsules by Using a Fully Auto Capsule Filling Machine?
Fully automatic capsule filling machines are pharmaceutical equipment designed for high-speed, precise and efficient encapsulation of powders, korrels, or pellets into hard gelatin or vegetarian capsules. These capsule making machines significantly enhance production efficiency while ensuring dosage accuracy and minimizing contamination risks.
the NJP-3800D fully automatic capsule filling machine
2.1 How High Is the Production Output?
Take the NJP-3800D model as an example— it boasts an impressive output of filling 228,000 capsules/hour, making it ideal for large-scale pharmaceutical manufacturing. Beyond high productivity, along with premium models, NJP-3800D automatic capsule filling machine features some advanced technologies including:
- Pneumatic feeding system for smooth material feeding and transferring.
- Modulair ontwerp forcomponent changeover and convenient maintenance.
- Dust-proof construction of the turntable, preventing cross-contamination.
- Optical indexing head helps dividers ensure filling weight variation to remain below 3%, guaranteeing dosage consistency.
2.2 What Are Advantages over Semi-Automatic Capsule Machines?
Compared to a semi auto capsule filling machine, a fully automatic capsule filler filling machine offers significant benefits:
- Higher production capacity: filling thousands or hundreds of thousands more capsules per hour.
- Reduced labor dependency: fully automated operation.
- Improved precision: lower filling weight deviation.
- Enhanced hygiene: enclosed systems minimize material contamination.
- More reliablequalification of finished products: automatic rejection of defective capsules.
2.3 Operational Steps of a Capsule Filling Machine Automatic
Stap 1: Loading Materials
Empty capsules are poured into the capsule feeding hopper, while the medicinal powder, granules or pellets are loaded into the filling hopper. For convenience, automatic capsule loaders and vacuum powder feeders can be utilized to automate this process, minimizing manual operation.
an auto capsule loader along with an auto capsule filling machine
Stap 2: Parameter Setting
Operators can configure the capsule maker machine via a PLC touch screen, adjusting parameters such as filling weight, capsule size, and production speed to meet specific requirements.
Stap 3: Automated Encapsulation Process
The capsule machine delivers fully automatic performance during the entire process without manual intervention:
- Empty capsule feeding – separates and aligns empty capsules.
- Capsule filling – precisely doses the medical ingredient into capsule bodies.
- Powder compression – ensures compact filling.
- Capsule locking – joins capsulecaps and bodies securely.
- Defective capsule rejection – removes improperly filled capsules.
- Finished product discharging – outputs completed capsules for further processing.
the main mechanism of a fully auto capsule making machine
Stap 4: Optional Post-Processing
To further preserve capsule quality and packaging efficiency, additional machines mentioned below can be integrated with a capsule vulmachine:
- Capsule polisher– removes possible residual powder on capsule surfaces for a cleaner appearance.
- Blister packaging machine – automatically seals capsules into aluminum-plastic or alu-alu blister packs for retail-ready, tamper evident packaging.
the capsule feeding mechanism of a blister packing machine
- Capsule counting machine — automatically counts capsules into bottles for accurate pharmaceutical bottling, making every bottle containing capsules of the same number.
the capsule separation process in a capsule counting machine
By minimizing human intervention and maximizing efficiency, auto encapsulation machines ensure consistent filling quality while reducing operational costs, making them indispensable in modern drug manufacturing.
3. How to Fill Capsules by Utilizing a Manual Capsule Machine?
A manual capsule filler is a simple, hand-operated device designed for accurately filling empty capsules with powdered medication, supplementen, or herbal formulations. Unlike automated capsule machines, it requires manual effort but is cost-effective and ideal for small-scale production, compounding pharmacies, or laboratory use.
Although a manual capsule filler is not as efficient as those automatic capsule filling machines, it’s really affordable and much cheaper. Wat meer is, it’s indeed portable.
Filling capsules with a manual capsule filler involves a straightforward, step-by-step guide:
Stap 1: Prepare Capsule Bases
Start by placing empty capsule bottoms into holes of the alignment plate. Ensure each one sits securely in an upright position to prevent misalignment during capsule filling.
Stap 2: Evenly Dispense Powder
Scoop the powdered medication and spread it over the dosing disc. The disc helps distribute powder uniformly into each capsule base, ensuring overall consistent dosages across all capsules.
Stap 3: Compact the Powder
Gently press down on the powder using the tamper to compress it. Repeat the process, adding more powder as needed, until the capsules reach the desired fill level. Proper tamping prevents under- or over-filling.
Stap 4: Seal Capsules
Position capsule tops onto the alignment plate, aligning them with filled bases. Use the capping plate to press the tops firmly onto the bottoms, ensuring a secure closure of capsules.
Stap 5: Final Check and Completion
Once locked, remove the capsules from the plate and inspect them. Verify that each capsule is properly locked and free of residual powder. Manual capsule fillers are ideal for small production batches, offering reliable consistency.
4. How to Fill Capsules at Home without Any Machine?
To make your own capsules by hand is a practical and cost-effective way to customize dietary supplements according to your needs. With just a few basic tools— such as a scale for accurate measurement of capsule ingredients, a spoon, a funnel, and storage containers— you can easily fill capsules at home. Below are two straightforward methods to help you get started.
4.1 Method 1: The Scooping Technique
This approach is the simplest, requiring minimal equipment.
Stap 1: Prepare Powder
Place your desired powder or herbal blend onto a clean, dry surface, such as a shallow dish.
Stap 2: Separate the Capsule
Gently twist the empty capsule to divide it into two halves— the body and the cap.
Stap 3: Fill the Capsule
The capsule body should be pressed into powder, using a scooping motion to pack it fully. Avoid overfilling the cap to ensure easy sealing.
Stap 4: Seal the Capsule
Align the filled body with its cap and press them together firmly but gently to secure the capsule.
This method is quick and easy, ideal for those who prefer minimal tools.
4.2 Method 2: The Spoon and Funnel Approach
For more accurate dosing, this technique incorporates a spoon and a makeshift or actual funnel.
Stap 1: Prepare the Powder
Spread your chosen powder evenly on a clean, dry dish.
Stap 2: Separate the Capsule
Detach the capsule into its two halves as before.
Stap 3: Create a Funnel
If you don’t have a funnel, roll a piece of paper into a cone shape, leaving a small opening at the bottom.
Stap 4: Fill the Capsule
Insert the narrow end of the funnel into the capsule body. Using a spoon, carefully transfer the powder into the funnel, allowing it to fill the capsule. Repeat for the cap if needed. For accuracy, weigh the powder beforehand with a scale.
Stap 5: Seal the Capsule
Once filled, join both halves and press lightly to close a capsule.
By following these methods, you can easily produce homemade capsules tailored to your preferences. Whether you opt for the scooping technique or the funnel approach, both methods ensure a manageable process. Store your finished capsules in airtight containers to maintain their freshness.
With a little practice, hand-filling capsules becomes an effortless task, offering flexibility and control over your supplement intake.
5. What Should You Know beyond Capsule Vulling?
Filling drug capsules involves more than just operating a capsule filler filling machine. Understanding capsule sizes and material choices is crucial for ensuring dosage accuracy, patient compliance and product stability.
5.1 Capsule Sizes: Finding the Right Size
Sizes of capsule vary in 8 types, with size 000 indicating the largest size and size 5 referring to the smallest size. The weight capacity of a capsule depends on the powder density.
Maat 000 capsules hold about 700–1,300mg of a light powder, while size 5 capsules hold only 60–130mg.
The most commonly used sizes are size 0 and size 1, as they accommodate average dosages comfortably. Echter, larger capsules (e.g., maat 000 of 00) are preferred for:
- High dosagedietary supplements (e.g., fish oil, herbal blends).
- Veterinary medicines (larger animals need higherdoses).
Omgekeerd, smaller capsules (e.g., size 3–5) are ideal for:
- Potent drugs (e.g., hormones, certain antibiotics).
- Pediatric or elderly patients who struggle with swallowing.
5.2 Gelatin Capsules VS Vegetarian Ones: Key Differences
| Gelatin Capsules | Vegetarian (HPMC/Pullulan) Capsules |
Materiaal | Derived from animal collagen (bovine/porcine) | Plant-derived cellulose (HPMC or Pullulan) |
Appearance | Duidelijk, glossy, smooth | Slightly opaque or matte |
Performance | Dissolves quickly (fast-release) | Slower dissolution, resists cross-linking |
Shelf Life | 2–3 years (best in low humidity) | 2–3 years (more humidity-stable) |
Drawbacks | Not user-friendly to vegetarians; may become brittle in dry conditions | Duurder; may need machine adjustments |
Choosing the right capsule size and material depends on the dosage, target users, and stability needs. While gelatin capsules are cost-effective and fast-dissolving, vegetarian ones cater to ethical and dietary preferences. Always consider these factors alongside capsule machine settings for optimal results.
Conclusie
Making your own capsules offers significant advantages, including cost savings and the ability to create personalized supplement blends. By mastering the process and using the right tools, you can produce high-quality, customized dietary supplements tailored to your specific needs.
For those seeking professional capsule filling equipment, RUIDA PACKING is a trusted pharmaceutical equipment manufacturer of premium capsule filling machines. Their strict quality control and compliance with industry standards ensure reliable performance for all your capsule production needs.
