After capsule filling, a sorting machine is needed to sort out defective capsules, like cracked or underfilled capsules. It greatly improves the quality of capsules and helps you get customer trust.
What is a capsule sorting machine?
A capsule sorting machine or capsule sorter is a machine used to separate good capsules from defective ones after filling. It could inspect each capsule and removes unqualified ones, including
- empty capsules
- broken or cracked capsules
- capsules with the wrong weight
- capsules with powder leakage
This equipment is usually installed after a capsule filling machine and before polishing or packaging. The machine identify defects based on the differences of weight, size, or appearance. Good capsules continue to the next step, while defective ones are rejected automatically.
Advantages of a capsule sorting machine
The capsule sorting machine plays a key role in the whole production line. It offers many advantages for capsule production.
- Better quality. The machine removes empty, broken, or abnormal capsules. It avoids that the defective products will reach the market.
- Higher efficiency. A sorting machine can check a large number of capsules in a short time. It is much quicker than human sorting.
- Accuracy. The machine could conduct precise sorting because of the advanced technology.
- Easy integration with other equipment. The sorting machine can easily connect with capsule filling, polishing, or packaging equipment. It fits well into an automatic production line.
Application of a capsule sorter
Capsule sorters are used in many production areas.
- The pharmaceutical industry. Capsule sorters are used in drug product manufacturing to remove empty or defective capsules after filling.
- The dietary supplement industry. In supplement production, such as vitamins, minerals, or herbal capsules, the sorter keeps product consistency.
- Herbal and traditional medicine. A sorter can remove abnormal capsules and improve the product uniformity.
How does a capsule sorter work?
A capsule sorting machine separates good capsules from defective ones based on differences in weight, size, or appearance. This sorting process is usually automatic and follows the following steps.
Material feeding
Put the filled capsules into the hopper. When the sorting machine is directly connected to the filling machine, they would be transferred directly. Capsules are then evenly spread onto a vibrating plate or track.
Alignment
In most production, the machine arranges capsules in order. It makes each capsule pass through the inspection area one by one.
Detection
The sorter checks each capsule with one or more methods
- Weight difference. It finds empty or underfilled capsules.
- Size or shape sorting. This detects broken or deformed capsules.
- Airflow. It separates lighter capsules from qualified pills.
- Camera inspection. This identifies surface defects, like dents.
In real production, many production lines combine two sorting ways. In most cases, the most common combination is airflow with size sorting. Airflow first removes empty or very light capsules, and then a screen is used to remove broken or deformed capsules. This combination has low cost and high speed, ideal for most production lines.
Separation and collection
Next, defective capsules are automatically removed. Rejected capsules are then collected. Meanwhile, qualified capsules move on to the next processing, like polishing or packaging.
What key parts does a capsule sorting machine have?
A capsule sorting machine is made of many parts. They are combined to complete the accurate sorting process.
Feeding hopper
The feeding hopper holds the capsules before sorting starts. Capsules enter the machine from this part, manually feeding or from a connected capsule filling machine.
Vibrating plate
This part spreads and moves the capsules forward. The vibration makes capsules flow in order and arrange them well. In this way, each capsule can be checked clearly in the next step.
Sorting unit
It is the key part of a sorting machine. It checks capsules with weight, size, airflow, or camera inspection. Different sorting equipment has different methods. For the airflow system, air suction or blowing is used to separate unqualified capsules from good pills.
Rejection part
The rejection system removes defective capsules from the production line after they are identified by the inspection unit. This part uses fast-response mechanisms such as air jets to separate capsules in real time. It features high speed and precise timing.
Control panel
The control panel manages the operation of the whole machine. Operators can set parameters such as speed, weight range, or airflow strength. Modern machines often use a touch screen for easy operation and monitoring.
How to select a capsule sorter for your business?
If you wonder which type is suitable for your business, consider the following factors.
Production capacity
First, check your daily or hourly output. Capsule sorters come in small, medium, and high-speed models. You’d better choose a machine that can handle your production volume and it won’t slow down your line. If overloading, the efficiency and accuracy could also be affected.
Easy adjustment
The sorter should be compatible with the capsule sizes you produce. Some machines can handle multiple sizes from #00-#5 automatically, while others require changing parts or adjustments. In this case, easy assembly and adjustment are considerations.
Smooth integration with your existing production line
The sorter should fit smoothly with your capsule filling machine and packaging equipment, such as a bottle filling or blister packaging machine. A smooth integration leads to a continuous and efficient automated line.
GMP compliance and safety
The sorting machine should meet GMP and local pharmaceutical or supplement regulations. It should use food-grade or pharmaceutical-grade stainless steel, such as 304 or 316L. All contact parts must be non-toxic, corrosion-resistant, and easy to clean.
How to maintain a capsule sorter?
Proper maintenance is helpful to keep the capsule sorting machine running well. It improves production efficiency and accuracy. You can follow these steps to maintain your equipment.
Daily cleaning
Clean the machine after each production shift. It could remove powder residue from the hopper, tracks, and sorting area. This prevents contamination and keeps the machine running smoothly.
Check key parts regularly
It is suggested to inspect parts such as the vibrating plate, feeding track, and rejection system once a week. You can check if there is any wear, blockage, or abnormal movement. If problems appear, replace that part in time. Early checking helps avoid sudden breakdowns.
Lubrication
You should also apply lubricant to moving components. This reduces friction and extends machine life. Please note that avoid over-lubrication, especially near product contact areas. You can choose the right lubrication type according to your manual guide.
Cooperate with Anxine to get high-quality sorting and polishing
As a leading Chinese manufacturer, Anxine has 14 years of experience specializing in pharmaceutical manufacturing. We offer capsule filling machines, tablet press and gummy making equipment. Anxine sorters are always integrated with a polishing function. These polishing and sorting machines could quickly move the extra powders and get high-quality capsules. The max capacity could be up to 600,000 pcs/h, ideal for capsule sizes from #00 to #4. If you need customization for more improvement, contact us freely.
