How Does a Capsule Filling Machine Work?

COMMON QUESTIONS WITH UNCOMMON ANSWERS

How does a capsule filling machine work? is a much more common question than one might think!

For example, you might have already asked yourself questions such as…

1. Why are there so many spoon kits on Amazon labeled as “capsule-filling machines?!”

2. Can you fill all capsules sizes with just one machine?

3. Does a capsule machine fill both a capsule’s top AND bottom side?

4. Do you have to put the capsules in manually one at a time?

5. Does it open the capsules for you?

6. How do you know how much powder fits into each capsule?

7. How does it join the capsules for you?

8. How could it fill capsules with oils?

These types of questions go on and on. Yet the answers are probably different than you’d think when you start out on your do-it-yourself journey.

Interesting Note: Before I got a capsule filler, I filled both sides of a capsule and pressed them together by hand. When I got my first machine, I learned that filling only one side of a capsule is how you measure the powder accurately.

THE 3 CATEGORIES OF CAPSULE FILLING MACHINES

To understand how they work, you’ll first need to choose what type of capsule-filling machine you’re interested in.

They all fall into 3 main categories: Manual, Semi-Automatic and Automatic.

Quick test to figure out what type you need:

1. If you’re making capsules at home or for a small business, you’ll be using either Manual or Semi-Automatic.

2. If you make capsules in-house for a large supplement line, you'll want Semi-Automatic or Automatic machines.

MANUAL CAPSULE MACHINES:

These are the most common and cost effective. Depending on the hole count, a manual machine can do anywhere from ~100 up to ~3000 capsules per hour.

• Example: Our Core Series and our Pro Series.

   

SEMI-AUTOMATIC MACHINES:

Semi-automatic means that one or more of the processes has been made automated by the capsule filler. For that reason, these machines come in many different varieties:

Some function more like manual capsule presses while others function more like an automatic capsule machine would. You can visualize this dichotomy by the following diagram:

Depending on the level of automation (and thus price/output per hour), a semi-automatic machine can fall anywhere on this line.

• *Note: Since there’s such a vast variety in semi-automatic capsule presses, we’re going to be discussing the most common type: Those which automate the capsule-separation process.

• Example: Our Pro-Op Series
  These machines use joined capsules, making it so you don’t have to separate them yourself one-by-one beforehand or buy pre-separated capsules, which are more expensive.

AUTOMATIC MACHINES:

Like semi-auto machines, there’s an enormous variety of different automatic capsule filling machines based on attributes such as output speed, filling processes and space requirements. These machines offer fully automated and continuous capsule filling at high speeds, reducing labor costs and increasing efficiency.

Fully automatic machines typically start around $60,000 and increase in price from there.

• Example: The SFK-700

HOW DO MANUAL CAPSULE-FILLING MACHINES WORK?

Manual machines are the most common because they’re not too expensive and they exist in models from the consumer level up to professional. Another reason is that they work better for certain substances that can be very difficult to encapsulate, those of which automatic machines couldn’t handle.

Basic Working Principle: Consists of multiple layers of plates, each with holes that are used for holding, guiding, aligning, joining and/or filling each side of the capsules.

Type of Capsule: Requires the use of separated capsules or that the capsules are manually separated beforehand.

How the Capsules Pieces are Loaded: Getting all the tops and bottoms into the holes only takes about a minute thanks to the “frame plate.” This piece has a funnel positioned over each hole that quickly guide all the pieces into their slots.

You simply pour in your capsule tops or bodies (depending on which side you’re loading) and shake! The pieces fall into the funnels and down into the holes below, preparing them for the next step very quickly.

How the Capsules are Joined: The main plate (most often called the “body plate”) holds the larger half of the capsules (called the capsule bodies) allowing you to pour and pack in your powder. It’s spring-loaded to so that the plates above can press down on top of it, ultimately snapping the capsule tops onto the bodies all at once. The most common manual machines hold anywhere from 24 to 800 capsule bodies at once.

• Example: Our Core Series and Pro Series lines are both perfect examples of the variety available within manual machines. With one of our 100 hole manual pill fillers, you can expect up to ~700 capsules per hour, or about 10 minutes to make 100 capsules.

To see exactly how a manual pill filling machine works:

• 1. Watch our How to Use Your Core Series Capsule Filling Machine video

  Or

• 2. Take a look at the picture instructions included with all our Core Series models.

ADVANTAGES OF MANUAL CAPSULE FILLING MACHINES:

• Low upfront cost: The most attractive benefit, making them readily accessible for individual users, small businesses, or experimenting with formulations.

• Compact and portable: Often small and lightweight, they require minimal space and offer portability for use anywhere.

• Simple operation: Easy to learn and operate with minimal training, requires no complex systems or technical expertise.

• Versatility: Can handle a larger range of capsule sizes and substances used to fill them with.

• Customization: Allows for adjustments and tailoring during the filling process, ideal for experimenting with different recipes or dosages.

• Little to no maintenance required: There machines are simple to use, which eliminates any expensive ongoing maintenance.

• No electricity needed: Manual means there is no dependence on electricity, and as such, can be used anywhere.

ANSWERS TO COMMON QUESTIONS:

Because manual capsule fillers are the most common type, we answered some of the questions that many new users have about them:

1. Why are there so many lab-spoon kits listed on Amazon with the title of “capsule-filling machine kit?!”

• As you may have guessed, these lab spoon kits are definitely not capsule filling machines. The reason they’re called capsule filling machines is that since Amazon banned the sale of all encapsulation and tablet-pressing devices in March of 2017, the closest items that are still allowed to be sold and preform the loosely-related task of filling one capsule at a time are these lab spoon kits. Therefore, since there are hundreds of people searching for capsule filling machines everyday on Amazon, this is the only such item that let’s you do it at all (albeit very inefficiently)!

2. Can you fill all capsules sizes with just one machine?

   • All capsule fillers at the consumer level are made specifically for one size capsule, and thus can’t be mixed and matched. There are some professional models that allow for the switching of capsule “size change parts,” but these typically cost in the thousands and require the change plate sets be purchased separately. See our Pro-Op 300 Series.

3. Does a capsule machine fill both a capsule’s top AND bottom side?

• A real capsule-filling machine, such as The BEAST™ 800 Hole Pro Series model only lets you fill the capsule bodies (larger halves) with powder or oil. The capsule tops (smaller halves) are then aligned and pressed down onto the bottoms, resulting in a filled and closed capsule. This ensures that every single capsule body is filled with the same amount of the powder, which is what allows you to calculate and fill each capsule with the exact dose you want!

• To learn how to do this properly, watch our short 2 minute clip on doing this here.

4. Do you have to put the capsules in manually one at a time?

• Fortunately, manual capsule fillers have a “Frame Plate.” This plate makes aligning your capsule tops and bodies with the other plates very quick and easy. You simply put the frame plate on top of the body plate, pour all the capsule bodies (bottoms) into the frame plate, shake it up, and the capsule bodies fall right into place in under a minute.

5. Does it open the capsules for you?

• Manual capsule fillers don’t separate the capsules for you, so you’ll need either pre-separated capsules, or you’ll have to separate them yourself before use.

6. How do you know how much goes into each capsule?

• Because each capsule body has a very specific capacity in mL, you can calculate how much each capsule holds by weighing a capsule after filling it. Or, if you need to make sure you put in a very specific dosage, refer to our short clip mentioned in question #2 above.

7. How does it join the capsules for you?

• Once you place all the capsule tops in the capping plate, all the bottoms in the body plate, and fill the capsule bodies with the desired powder, then all you have to do add the middle plate (to hold the capsule tops from falling out) and then flip the capping/middle plate over onto the body plate and press down firmly. You’ll hear them all snap shut, leaving you with rejoined, filled capsules.

8. How could it fill capsules with oils?

• Filling capsules with oil is a little different than powder because it requires you to use a liquid syringe and carefully fill each body one by one in a methodical, grid-like fashion. Once they are all filled, you simple follow the same steps as you would for powder and press the tops onto the oil-filled bottoms.

  *Note: Why would you need an oil syringe?

  • This is because oil gets everywhere, and you want to make sure as much of the oil gets into the capsule as possible without too much spillage. Spillage may not only waste your expensive oil supplements, but any oil on the outside of the capsule bodies may interfere with the natural air-release action that happens when pressing capsules together. The extra oil may cause a much stronger seal against the airs natural escape route, which could result in some of the capsules not pressing together correctly. The best way to ensure this doesn’t happen is by using a n oil syringe and filling each capsule in a rapid but methodical motion (a little spillage is expected though.. that’s ok!)

HOW DOES A SEMI-AUTOMATIC CAPSULE PRESS WORK?

The Semi-Automatic Capsule Presses we’re describing here separate capsules for you, letting you use joined capsules instead of pre-separated ones.

Type of Capsule: Joined

The basic working principals is the same as with the manual machines, except that this has two extra mechanisms:

1. A capsule-orienting tray that quickly organizes and drops your joined capsules face-up into the holes of the machine.

2. A capsule-separation mechanism that locks the capsule bodies in place, allowing you to freely lift the capsule tops off all of the bodies at the same time.

The remaining ideas are nearly identical to the manual types, yet with a few more convenient aspects that accelerate the filling and re-joining processes.

To see how this works, take a look at our Pro-Op Series 100 Hole picture instruction manual.

ADVANTAGES OF SEMI-AUTOMATIC MACHINES:

• Lower upfront cost: Significantly cheaper than fully automatic machines, making them ideal for small-scale production or starting businesses.

• Compact and portable: Often smaller and lighter than automatic machines, requiring less space and offering portability for flexible use.

• Simple operation: Easier to learn and operate compared to complex automatic machines, requiring less training for users.

• Versatility: Can often handle a wider range of capsule sizes and filling materials compared to some automatic models.

• Flexibility: Allows for customization and adjustments during the filling process, suitable for experimenting with different formulations.

• Lower maintenance costs: Generally require less maintenance and repair compared to advanced automatic machines.

HOW DOES AN AUTOMATIC CAPSULE FILLING MACHINE WORK?

As mentioned earlier, automatic machines all have their own unique and specific mechanisms for getting the job done. Regardless what those mechanisms are, the result is a fast, continuous output of filled capsules.

Describing the many specific ways automatic machines work would fill up a dozen books or more. However, most automatic machines have the same general steps:

1. Loading and Separation: Bulk empty capsules are loaded into a large hopper or system that continuously feeds them in during production. Through vibration or suction actions, the capsules are separated into tops and bodies before being aligned for filling. Here some machines may even preform a quick cleaning or inspection before proceeding to ensure smooth filling

2. Dosing and Filling: The bodies are then filled to their exact and desired proportions based on user-set preferences.

   Some examples include:

   • Tamping Pins: Picture a rotating disc studded with tiny tampers. It dips into a powder reservoir, packs it tightly, and transfers it with pinpoint accuracy into waiting capsules.

   • Dosators: Imagine a specialized tool dipping into the powder, forming perfectly sized "slugs," and then injecting them directly into each capsule body, like a synchronized dance of precision.

   • Auger Screws or Volumetric Chambers: These are able to take a continuous flow of powders or liquids and dispense precise amounts into each capsule.

3. Joining and Sealing: Robotic arms or conveyor belts precisely align and join the filled capsule bodies and caps. To finish, pressure systems, ultrasonic welding, or even heat sealing methods securely close the capsules.

4. Ejection: The finished capsules are then ejected onto a collection tray, conveyor belt, or counting system where they'll be taken for the next stages such as cleaning, inspection, and/or packaging.

ADVANTAGES OF AUTOMATIC MACHINES:

• Highest capsule output capacity: Can fill thousands more capsules per hour compared to manual machines.

• Most consistently accurate : No humans means no human error, leaving you with the same precise dose in each capsule.

• Reduced labor costs: Automates the entire filling process, minimizing the need for manual intervention.

• Data tracking, organization and more: Some models offer features like recipe management and data logging for greater production efficiency.

  To see one in action, check out this video.

CAPSULE FILLING MACHINES - MORE TO LEARN

Those are the basics for how most capsule fillers work, and how they’re able to fill and join multiple capsules at a time.

For help choosing which machine works best for you, read one of our latest articles, How to Choose the Best Capsule Filling Machine: An In-Depth Guide for 2024 and Beyond.

BlateCo specializes most closely in manual and semi-automatic capsule filling machines. We’re extremely passionate about capsule machines, capsules and their ingredients and our many other products that serve the same purpose.

To see what capsule filling machines we offer, head to our online store and learn about the hundreds of machines we ship everyday from our warehouse in Jacksonville Beach, Florida.

There’s always more to learn and new equipment coming out. If you have any questions about any devices in particular, we’re always happy to answer them!

To do so, you can comment below or reach out directly via our contact page.