AIPAK Capsule Counting Machine

1.What is a capsule counting machine?

AIPAK capsule counting machine

A capsule counting machine is an astonishing device thatipped with a photoelectric sensor allows a high precision e ensures the presence of capsules accurately and fills them into respective containers or polybags; equspecially needed for counting and filling.

Capsule counting machines are ideal for small to large size productions. They are suitable for commercial, laboratory, and industrial applications. A capsule counting machine is designed to meet quality standards such as cGMP, CE, etc.

This machine ensures patient medication protection and safety, fast processing, and increase efficiency. Modern capsule counting equipment is automatic and operates under the control of a micro-controller.

Capsule counting machine with state-of-the-art allows effortless capsule counting experience that you'll love to know.

2.What is the working principle of the capsule counting machine?

It is important to have knowledge about the working mechanism of machines for better operation. Let us understand each step;

First step: Program Setup

• • This step requires the user to set desired counting parameters on the machine.

 

• • It also requires the user to fill capsules in the automatic filler and ensures the practicality of all machine components.

 

• • At this step, user active input is necessary.

 

Second step: Capsules Supply to the Machine

• • At this step, capsules pass through the automatic filler and enter into the hopper.

 

• • Capsules from the hopper flow into the feeder trays made up of stainless steel and the hopper also regulates the number of capsules passing through it.

 

• • There is another component "hopper sensor" in the machine which helps in regulation of capsules level in the stainless-steel feeder trays without process interruption.

 

• • Subsequently, capsules flow slowly into the conveyor belt by automatic vibration.

 

Third step: The Real Counting

• • Flow of capsules to the next component depends on the speed of stirring of conveyor belt which can be adjusted.

 

• • The next key part is the "sensor"which detects the capsule when it passes through it and records its count which is visible on the computer screen. In addition, it also assists in detection of defected capsules with improper colors, weight, sizes, and broken pieces.

 

• • Photoelectric detectors are other alternatives which facilitate capsules counting.

 

Fourth step: Automatic Capsule Filling

• • Subsequently, the required number of capsules automatically add into the package for downstream sealing and packaging.

 

• • There is an efficient rejection system in the counting machine which accurately segregates appropriate capsules from unacceptable capsules.

 

• • The operation of the capsule counting machine is continuous and does not stop until the desired count of capsules is achieved.

 

Basic Working Structure of Capsule Counting Machine

The entire process is controlled by an advanced electronic micro-computer system that counts and scans dynamically so medicines in each filling container may distribute evenly. In case of error, the capsule counting system automatically stops working and assesses the cause of the error.

3.What are the basic parts of a capsule counting machine?

Hopper

This is for storing and loading capsules to be calculated. There is an adjustable baffle present at the exit of the hopper. This adjustable baffle can be modulated according to the output volume of capsules. You can easily take out the hopper for easy cleaning.

Vibratory Feeding Track

Capsule counting machine has been adopted with multi-grade vibrators. You can control the vibratory speed according to the flow and quantity of capsules. The vibratory feeding track is accompanied by a small gap on the front of the feeding track to clean the dust from capsules and collect.

Photoelectric Detection Device

This machine offers superb benefits via intelligent automatic capsule counting device. It results in accurate, fast, and cleaned output.

Touch Screen

Automatic capsule counting machines are adopted with touch screen PLC system where you can set the required parameters, start, and stope the process and monitor the real-time data as well as failure warning.

Vibrating Channel

Capsule counting machine is installed with vibrating channels to distribute the capsules smoothly and evenly.

Bottle Conveying Unit

This unit is integrated with drive system, a conveyor belt, and a bottle pause cylinder, an illuminating sensor etc.,

Adjustable Lifting Base

Capsule counting machine structure is lifted on adjustable base that ensure easy integration and protects the body.

4.What are the types of capsules counting machines?

Capsule counting machines are available in different types based on their mode of operation. In general, they can be of following three types;

• • Manual capsule counting machines

 

• • Semi-automatic counting machines

 

• • Automatic counting machines

 

Manual Capsule Counting Machines

• • Manual capsule counting machine used for various kinds of capsules via manual technique for capsule counting.

 

• • It is ideal for counting small scale batches of capsules in pharmaceutical, chemicals, foods industries

 

• • Easy to operate and maintain.

 

Semi-Automatic Counting Machines

• • It utilizes both automatic and manual machines programs.

 

• • It is a compact and highly efficient machine that can easily count and pack the capsules into assign containers or bottles.

 

• • It offers reorganization/restructuring of programs as per user requirements.

 

Automatic Counting Machines

• • Suitable for counting large batches of capsules in pharmaceutical industries

 

• • Offers high accuracy in bulk counting

 

• • Use of advance technologies and unique algorithms make these machines highly appropriate for counting

 

• • Reduces the need of human involvement

 

 

5.What are the applications of capsule counting machines?

Capsule counting machines are critical component of a number of organizations including;

Retail Pharmacies

Instead of adding number of staff capsule counting machine is an efficient solution for that can save your time and reduces the chances of error.

Pharmaceutical Industries

Capsule counting machine market is rises with the growth of pharmaceutical industries. Automatic capsule counting machine can detect damaged or faulty capsules, capable enough to deal with bulk production batches, easy to handle, and increases profitability.

Pharmaceutical industries deal with patient care and for this reason accuracy in each step of the production processes is the fundamental need of these industries.

Veterinary Hospitals

Fast and accurate capsule counting machine are considered as most demanding solution in veterinary hospitals.

Primary Care Hospitals

Capsule counting machine are significantly used in prestigious network of private and government hospitals who manages the largest number of inpatient and public health outreach.
Capsule counting machines offer fast processes with high accuracy because any error in counting may alter drug dose in a package that may cause detrimental effects on a patient's health.

Chemical Industry

In comparison to hospitals, and pharmaceuticals- chemical industry also broadly use capsule counting machine for safe, accurate, and fast counting of chemical-based capsules respectively.

Food Industry

Capsule counting machine has wide usage in food processing and confectionery industry to count pills contain food ingredients.

Secondly, accuracy in capsules counting is also required for finalizing the justified rate of products, any error in counting may cause industry financial loss customer compliance over the flawed product.

Cosmetic Industry

Capsule counting machine is beneficial for various purpose in cosmetic industry such as, counting of facial serums, and oils.

6.Describe five basic advantages of capsule counting machines?

Innovative and modern technology of capsule counter hooked with numerous benefits. Here are five major advantages of a capsule counting machine that you must know!

#1-Timesaving

Have you ever imagined sorting, counting, and dispensing thousands of capsules with different shapes, sizes, and colors by hand?

Indeed, it is troublesome and would take hours and hours to complete this task. Besides this, you would encounter with risk of human errors during handling. Not only this! If you find some staff shortage, it would be ample of burden that hampers productivity and backlog of work.

So, a rescuer can automatically here to save you from such a burden by relieving the workload of staff and offering you a more intelligent job. Instead of extra hands, it offers less space occupation and more efficient results.

#2- Cost-Economical
As we discussed above, manual handling can be cheaper, but you will be surprised to know it is more costly when you convert their working hour in money. A capsule counting machine is not only timesaving but it will cut down your staff expense by offering automatic, accurate, and fast output at a one-time cost.

#3- Accuracy & Precision
If an employee commits a mistake, you'll need to re-start counting all over again. Indeed, it is hectic and a loss of time. If you 'feed' input to the machine and rest is on the machine's ability to produce the results. The prime objective of the capsule counting machine is to assist you in accurate counting and boost your working efficiency procedures.

#4- No- Cross Contamination
You can wear gloves, and other necessary PPEs but what do you think- will it save you from cross-contamination while handling? A capsule counting machine has negligible chances to aggravate the risk of contamination while activities.

#5- Customer Satisfaction

If you get inaccurate capsules, in the wrong bottles, so will you accept them? A capsule counter machine ensures high customer satisfaction by offering an amazing counting solution with sensors and auto-detector that do not allow such instances to happen.

7.What are the differences between capsule counting machine?

 

 

Automatic Capsule Counting Machine	Semi- Automatic Capsule Filling Machine	Manual Capsule Counting Machine
Ideal for Larger Batch Production.	Suitable for precise production for pharmaceutical procedures.	Ideal for small batch production in pharmaceuticals, clinics, research institutes.
This machine can count and fill thousands of capsules per hour with high accuracy.	This machine ensures higher automaticity as compared to manual, count 25,000 to 47,000 capsule/ hour.	Capsule counting capacity of manual counters are minimum and produces up to 300 capsule/cycle and the operating speed depends upon the technician.
Entire procedure is performed automatically in continuous motion.	Procedure is so much like automatic machines, except pushing lever to load capsules and collections.	Working procedure is simple and based on hand operated procedures.

 

8.How to clean and maintain capsule counting machine?

Regular maintenance and cleaning arethe required processes for improving function of capsule counting machines as it is important for any other industrial equipment.

Process of cleaning is quite simple but users should perform it on a regular basis (usually in a week) or early if the machine is showing errors or output is not optimal or numerous dust producing drugs are being processed in the facility in which the capsule counting machine is installed.

There is an automatic reminder application installed in the machine for regular cleaning which is editable and a user may change some of its features including cleaning frequency.

It is required to switch off the counting machine before cleaning.

70% isopropyl alcohol and distilled water are required for cleaning mainly, however it may also require digital screen cleaner, paper towel and mild soap.

Guidelines about cleaning of each component of the counting machine are mentioned below.

Cleaning of Funnel

Detach it from the machine, carefully and thoroughly clean the inside and outside surface of funnel with alcohol and slightly soapy water

Glass Detector Screen Cleaning & Maintenance

• • There are two round thumbscrews on the uppermost side of the machine, user can unbolt them to disconnect square guards.

 

• • Then, elevate the complete channel assembly.

 

• • Subsequently, wipe the dust accumulated on four detector screens with the help of dry cloth.

 

• • Next, to make the glass windows (all four) dirt-free, clean them using a neat cloth wet in alcohol or slightly soapy water. At this point, care should be taken, and you should clean in all directions but not up and down.

 

• • Wipe the glass windows and dry them to prevent streaks using a digital screen specific cleaning cloth.

 

• • At this point, visual inspection is essential, you can carefully check the inside and outside of the channel assembly, particularly the glass windows for dust or particles. If you find dust or marks, wipe them once again using distilled water and dry.

 

• • At the end, fix the inner channel assembly again and reconnect the square guards by adjusting the round thumb screws.

 

• • After that, gently press down/depress the sliding ring which unrolls the two black clips connecting the glass window holder.

 

Counting Tray Cleaning

It is not recommended to use alcohol for cleaning of the counting tray. Use of lightly soapy water only is sufficient.

Tray Sensor Cleaning

• • Tray sensor is installed behind the counting tray, it senses the placement of tray and conveys the message to the unit whether the placement is right or not.

 

• • For cleaning, detach it from the unit and use distilled water for cleaning then wipe and dry to prevent streaks.

 

Cleaning of Touch Screen

• • It is recommended to use glass cleaner without ammonia for cleaning touch screens. Spray it on a neat, lint-free cloth and use it for cleaning. Do not direct spray on the touch screen.

 

• • Inspect visually, clean it again if there is any dust.

 

9.What is the basic troubleshooting of the capsule counting machine?

Troubleshooting Guide

In this guide, you will find a list of possible errors that you may experience while working with a capsule counting machine along with possible solutions that you may exercise to solve issues for better operation.

Ⅰ.Problem: Unit counts by itself

Reasons:

• • This problem arises due to a damaged detector glass window.

 

• • It may also occur when there is tablet dust or residue contamination on detector glass.

 

Solutions:

• • Regular cleaning of detector glass screens as recommended above.

 

• • Replace the damaged detector with a new one for optimal results.

 

Ⅱ.Problem: Over-count of pills

Reasons:

• • Due to tablet/capsule fragmentation

 

• • It may also occur when there is tablet dust or residue contamination on detector glass screens.

 

Solution:

Regular cleaning of detector glass screens as recommended above.

Ⅲ.Problem: Undercount of pills

Reason:

It occurs due to improper handling, when a user nonstop rapidly adds capsules into the funnels or adds straight into the funnel hole.

Solution:

Transfer the capsules into a funnel at moderate speed to avoid process interruption.

Ⅳ.Problem: Counting tray is pushed in yet display indicates "--" in place of "0000".

Reasons:

• • It may occur due to dust or contamination on the tray sensor.

 

• • It may occur due to improper insertion of the counting tray.

 

Solutions:

• • Regular cleaning of tray sensor as recommended above.

 

• • Properly set in the counting tray

 

Ⅴ.Problem: Counting tray is not properly set in yet display indicates "0000".

Reason:

It may occur due to dust or contamination on the tray sensor.

Solutions:

• • Regular cleaning of tray sensor as recommended above.

 

• • Repair the tray sensor screen if it is damaged.

 

Ⅵ.Problem: Inaccurate excess discharge of capsules per package

Reason:

It may occur due to loosening of screws of appendage for changing direction for discharge.

Solution:

Carefully tighten the screw

Ⅶ.Problem: Malfunction of panel display, the numbers are not changed

Reasons:

• • Strong light

 

• • May occur due to improper plugging in of sensor socket

 

• • Loosening of welded dot or interruption of internal coppermay lead to poor linkage of protecting wire plug.

 

Solutions:

• • Relocate the equipment to indoor

 

• • Properly re-plug the socket

 

• • Re-wiring or re-welding

 

Note: In the above-mentioned problems, the sensor indicator may not brighten up.

Ⅷ.Problem: Wrong capsules counting

Reasons:

• • Fast counting speed

 

• • May occur due to fragment contamination

 

• • May occur due to overlapping of capsules /tablets when feeding hopper is very high

 

• • May occur due to concealing of sensor by powder

 

• • Unfit location of counting machine which may expose it to sunlight.

 

• • High exposure to indoor natural light.

 

• • Sensor may damage

 

• • Loosening of welded dot or interruption of internal copper may lead to poor linkage of protecting wire plug.

 

Solutions:

• • Decrease the counting speed

 

• • Remove fragments

 

• • Hopper height re-adjustment

 

• • Sensor cleaning

 

• • Sensitivity re-adjustment

 

• • Relocate the counting machine to the indoor

 

• • Reduce the indoor light

 

• • Re-wiring or re-welding.

 

Ⅸ.Problem: Vibrating noise

Reasons:

• • May occur due to loosening of vibrating tray screw

 

• • The outer opening of the vibrating tray may link to the inner opening of the discharging channel.

 

• • The block equipped inside the machine and hexagonal screw located on the lower part may not be detached/disconnected.

 

Solutions:

• • Tighten the screw may resolve the problem

 

• • Vibrating tray re-adjustment

 

• • Detachment of the block and the hexagonal screw.

 

Note: The sensor indicator (LOAD) will brighten up when the counting machine is switched on and disappears automatically after 1.5 seconds, at this point the machine is considered ready for counting. However, if the display does not show "0000", it should be readjusted to "0000".

10.What are the major consideration points that you must know before purchasing a capsule counting machine?

Counting machines are considered as an important component of food, hospital, pharmaceuticals and other industries. It is actively used for counting capsules, granules, tablets or food.

Taking its applicability into consideration, the counting machine is a type of equipment that remains under development which becomes easier with the advent of highly precise advanced microelectronic, electronic, and packaging skills.

There are various models of counting machines made by different manufactures available. Therefore, you should consider the following points when buying capsules counting machines.

Practicability

Think about its workability, whether it is applicable to different types of samples or it is specific to only one dosage form. In pharmaceutical industries, there are many products for which counting is required for example; sugar coated tablets, plain tablets, soft capsules etc., therefore it is very important that the counting machine can be used for a large number of samples. It will save industrial cost and minimize the space needed for many equipment.

Is the operation trouble-free?

There are many characteristics which can tell you about the ease of operation.

For example;

• • Investigate about the working operation of equipment whether it is automatic or not and to what extent it requires human involvement.

 

• • Investigate about equipment adjustability whether it allows modification in operation parameters easily.

 

• • Also, investigate the cleaning and maintenance protocols whether it is simple to maintain and repair the equipment because you will be using it for prolonged duration and cleaning is the fundamental requirement for better operation.

 

Counting Accuracy

This is one of the primary considerations before purchasing a counting machine. The accuracy of counting tablets/capsules should be 99.5% or above.

Safety

• • First consideration is that the machine should be safe to the products means it will not damage drugs during counting operation.

 

• • Secondly, it is also important that the equipment remains stable for a longer time. It should be equipped with safety devices that protect it from damage and short circuit.

 

Brand Price/ Budget

You should choose a brand that ensures the best quality of machine at a fair price and those who guarantee you of good services in case of any faults in the machine.

Hardware and software

You should choose a model that is advanced and has updated hardware and softwares. It will facilitate smooth operation.

Production Size

You should choose a counting machine that best suits your production capacity, meaning it can efficiently count the number of capsules/tablets you manufacture.

Quality Agreement

You should select the equipment that satisfies quality standards.

Expertise Needed

You should choose a model that requires minimal level of advanced expertise and is easy to operate. Because if you select equipment that fully requires new expertise, you will have to put efforts and money for additional training.

Conclusion

Capsuling counting machine is much needed equipment in pharmaceutical industry. This is all because of high technology, high- speed, and excellent accuracy. When searching for the best capsule counting machine. We recommend you AIPAK Pharmaceutical Machinery best series of capsule counting machines. Because they're the top-leading company in the designing, and creating of compact, convenient, and innovative capsule counting machine with high processing speed.