Automatic Powder Capsule Filling Machine for Pharmaceutical & Nutraceutical Manufacturing (NJP-1200)

The tamping pin system is specifically engineered to handle difficult-to-fill powders that other technologies struggle with. Here's why it excels:

• Low-Density & Fluffy Powders: Herbal extracts, some APIs, and nutraceutical blends have very low bulk density. The tamping pins progressively compress these powders in multiple stages, creating a uniform, dense slug that fills the capsule without air pockets or inconsistent weights.
• Cohesive or Sticky Powders: Powders that tend to clump (e.g., hygroscopic materials) are compacted by the tamping action, forcing them into the dosing cavity and preventing bridging or voids.
• Fine Powders with Poor Flowability: Unlike dosing disc systems that rely on gravity flow, tamping pins actively push the powder into the capsule, ensuring complete fills even when powder doesn't flow freely on its own.

Our NJP-1200 features a 5-station tamping mechanism, which provides superior compaction consistency compared to 3-station designs, resulting in tighter weight variation and fewer rejects.

The NJP-1200's modular design was specifically created to minimize downtime and meet cGMP cleaning validation requirements. Here's what you can expect:

• Cleaning Time: 15-20 minutes – All product-contact parts (dosing plate, tamping pins, powder hopper, and capsule segments) can be removed without tools. Simply release quick-lock clamps, remove the parts, and clean them separately or in your parts washer.
• Mold Changeover (Different Capsule Size): 10-15 minutes – Change parts (dosing disc, segment rings) are pre-assembled and indexed, so switching from size #0 to size #00, for example, is a fast, error-free process.
• Total Batch Changeover: Under 30 minutes – From shutting down the previous run to starting the new product, including cleaning, reassembly, and parameter adjustment on the HMI.

This speed is a game-changer for contract manufacturers (CMOs) or facilities producing multiple SKUs, as it dramatically increases daily throughput and reduces labor costs.

Absolutely. Pre-purchase testing is a core part of our service. We understand that every powder formulation behaves differently, and we want you to have absolute confidence before making an investment.

Here's what we offer:

• Lab Testing at Our Facility: Send us 1-2 kg of your powder formulation (under NDA if required). Our engineers will run filling trials on the NJP-1200, testing different tamping pressures, dosing disc configurations, and capsule closing parameters to optimize for your specific material.
• Comprehensive Test Report: You'll receive a detailed report including: achieved fill weight accuracy, fill success rate, capsule defect rate, recommended machine settings, and sample filled capsules for your review.
• Virtual FAT (Factory Acceptance Test): If you cannot visit in person, we'll conduct a live video FAT, demonstrating the machine running with your powder and answering your questions in real-time.
• On-Site Pilot Testing (For Large Projects): For high-volume contracts, we can arrange for a pilot machine to be installed at your facility for extended testing.

This commitment to testing ensures there are no surprises when the machine arrives at your site—it will perform exactly as promised.

We provide a complete validation documentation package to support your GMP qualification and regulatory submissions. Every NJP-1200 shipment includes:

• IQ (Installation Qualification) Protocol: Pre-written checklist covering equipment identification, utility connections (electrical, vacuum, compressed air), component verification, and safety interlocks. Includes blank forms for your QA team to complete during installation.
• OQ (Operational Qualification) Protocol: Test procedures to verify that the machine operates correctly across its full operating range (all capsule sizes, speed settings, tamping pressures). Includes acceptance criteria based on design specifications.
• FAT (Factory Acceptance Test) Report: Certificate documenting that the machine passed all performance tests at our factory, including fill weight accuracy data, capsule separation success rate, and speed validation.
• Material Certificates: Mill certificates for SS316L contact parts, confirming compliance with pharmaceutical-grade stainless steel standards (ASTM A240).
• Electrical & Safety Certificates: CE marking certificate, electrical schematic diagrams, and safety compliance documentation.
• Software Validation (If Required): For clients needing 21 CFR Part 11 compliance, we can provide software design specification, validation protocols, and audit trail documentation for the PLC/HMI system (additional fee may apply).

All documents are provided in English and can be customized to align with your company's validation templates and regulatory authority requirements (FDA, EMA, WHO, etc.).

The capsule polisher is an optional add-on, and whether you need it depends on your product presentation requirements and downstream processing.

What the polisher does:

• Removes surface powder residue: After filling, capsules may have fine powder dust on their exterior. The polisher uses soft brushes and a gentle vacuum to remove this dust, leaving capsules clean and shiny.
• Sorts and ejects defects: Our polisher includes an inspection station that automatically rejects capsules with visible defects (dents, cracks, misaligned caps).
• Prepares capsules for bottling: Polished capsules look more professional and are less likely to cause contamination issues in your filling/packaging line.

Do you need it?

• Yes, if: You're producing consumer-facing products (retail supplements, OTC medications) where appearance matters, or if you have strict cleanliness requirements for downstream bottling equipment.
• Maybe not, if: Your capsules go directly into bulk containers for further processing, or if you already have a separate polishing/sorting system.

We recommend the polisher for 90% of our pharmaceutical and nutraceutical clients as it significantly improves product quality and reduces manual labor. We can provide a bundled quote or add it later if your needs change.