📋
Technical Proposal
We are pleased to present our comprehensive technical offer for the Hard Capsule Manufacturing Machine Model: Samradh, specifically engineered to meet your production requirements. This state-of-the-art machine represents the pinnacle of pharmaceutical manufacturing technology, combining advanced servo-driven systems, precision engineering, and intelligent automation.
Our Samradh model delivers exceptional performance with a nominal production output of 2,30,000 capsules per hour. This proposal outlines the complete technical specifications, construction details, and premium components that make this machine the ideal choice for your manufacturing needs.
⚙️
Technical Specifications
Upper Deck Drying Zone
8 Zones
Lower Deck Drying Zone
7 Zones
Pinbars per Zone
32 × 4 = 128
Pinbar Width
22.22 mm
Pinbar Length
670 mm
Pinbars per Dipping Stack
8 units
Pinbars per Block
32 units
Total Pinbars on Machine
1,952 units
Pinbars Supplied (Cap)
2,100 units
Pinbars Supplied (Body)
2,100 units
Total Pinbars Supplied
4,200 units
Machine Length
25.0 metres
Machine Width
2.0 metres
Machine Height
2.0 metres
Nominal Production Output
2,30,000 capsules/hour
🏭
High Capacity
1,952 pin bars on machine with 4,200 total supplied for continuous operation and flexibility
⚡
Advanced Control
Fully servo-driven with triple PLC system for precise automation and temperature control
🏆
Extended Drying
15 total zones (8 upper + 7 lower) with 25m length for optimal capsule drying
◆ Construction Details ◆
- Exclusively powered by servo motors for optimal control and precision
- Cap and body spinning rotations (1.5 turns) driven by dedicated servo motors on each side
- Servo-driven elevators with direct-coupled ball screws, guided along dual LM guideway shafts
- Stack pushing assembly with servo motor and rack-and-pinion arrangement
- Single pin bar tilting operated using servo motor
- Brass elevators independently controlled by two programmable servo motors via HMI
- All linear motion components employ LM guideways with bearings for rotary movement
- Designated for pin bar polishing with reciprocating tables and specialized polishing heads
- Independent servo motors manage table reciprocation for cap and body
- All tables rest upon LM guideways for smooth operation
- Polishing heads designed for rapid removal and installation
- Driven by induction motors through gearboxes
- Spring-loaded polycarbonate greaser shells
- Greaser Parking feature enables on-the-fly removal without halting operations
⚡
Automatic Heads Section
▼
- Utilizes camshafts and mechanical cams for collet, pushrod, lifting, cutting, and stripping
- Cams hardened to 50+ HRC for sustained high-speed activity with minimal wear
- Unified Stripping Device (USD) eliminates stripper holes and reduces wedge/stripper changes
- Key moving elements guided by LM guideways (collet bracket, pushrod bracket, blade rack)
- Front bracket with precision-engineered hardened bushes for accurate collet alignment
- Optimized for reliable capsule transfer during high-speed operation
- Pneumatically actuated table lifting with optional servo-driven lifting
- Proprietary C-curve replaces traditional tilting section for smooth transitions
- Mitigates fall risk at elevated speeds during vertical to horizontal transition
- Additional 4-5 pin bars serve as buffer during capsule unloading
- Servo-operated pin bar pusher with fast return and gradual forward movement
- Cushioning system for reduced impact and accurate placement
- Frames utilize 145×85 mm mild steel piping with stainless steel rollers
- Bearings enable frictionless pin bar transit throughout the machine
- Top and bottom pushers operate along LM guideways
- Servo-driven via rack-and-pinion systems for precise control
- Rear tables function pneumatically with optional servo control
- Robust construction for long-term reliability and minimal maintenance
🔲
Block Design & Configuration
▼
- 15 total drying zones: 8 zones on upper deck and 7 zones on lower deck
- Each zone contains 128 pinbars (32 × 4 configuration) for high throughput
- Pin bars in each block are mounted on independent aluminium plates
- Hardened aluminium support plates ensure longevity and maintain precision
- Chain drive system with adjustable tensioning for synchronized movement
- Servo-driven central line with rack-and-pinion mechanism
- Robust construction for long-term reliability and minimal maintenance
🔄
Central Line & Capsule Suction
▼
- Guide rails (T-bars) manufactured from toughened steel for enhanced longevity
- Bottom suction system for capsule trimmings extraction
- No overhead chutes for improved operator visibility
- Dual cyclone separators manage trimming collection after cutting process
- Efficient material handling system reduces waste and improves cleanliness
- Optimized airflow design minimizes dust and contamination
- Stainless steel construction for high corrosion resistance and long service life
- Aluminium air outlet sheets with venturi holes for quiet, consistent drying
- Dual-sided adjustable kiln brackets ensure precise alignment
- Internal intermediate sheets promote uniform air distribution
- Air inlet pockets installed per customer requirements
- Standard inspection and temperature sensor ports
- 15-zone configuration (8 upper deck + 7 lower deck) for optimal control
- Extended 25-meter drying length for superior capsule quality
💻
Electricals & Automation
▼
- Three integrated PLCs: digital processes, servo operations, and temperature regulation
- Prominent 12-inch HMI at front left corner of dipping section
- Comprehensive temperature management and system calibrations
- PID parameter tuning and motor/pump activation control
- Real-time monitoring of viscosity, temperature, humidity, and alarms
- Individual temperature control per drying zone via standalone PID controller cards
- Closed-loop regulation with SSRs and PT100 sensors for precise feedback
🔧
Premium Bought-Out Components
Our commitment to quality is reflected in our choice of world-class components from industry-leading manufacturers, ensuring reliability, longevity, and optimal performance.
| Component |
Manufacturer |
| Ball bearings, roller bearings, taper roller bearings | SKF, FAG, NTN |
| Linear bearings | NB Japan, IKO Japan |
| LM Guideways | Hi-Win Taiwan |
| Ball screws | Hi-Win Taiwan |
| Planetary Gearboxes | Li Ming, Taiwan |
| Worm Gearboxes | Bonfiglioli |
| PLC & Servos | Mitsubishi, Siemens, INVT |
| Power Cable | LAPP |
| Switchgear | Schneider |
| Temperature sensors, heat sinks | Indian |
| Contacts, Connectors | Phoenix, Wago |
| Fasteners | Grade 12.9 toughened |
◆ Key Advantages ◆
Engineering Excellence
- Fully servo-driven precision control systems
- LM guideways throughout for smooth operation
- Hardened cams (50+ HRC) for sustained performance
- Unified Stripping Device (USD) concept
- Extended 25-meter drying length
- 15 independently controlled drying zones
Operational Benefits
- Minimal maintenance requirements
- Enhanced operator visibility and safety
- Real-time monitoring and diagnostics
- Easy changeover and quick setup
- High capacity with 4,200 supplied pinbars
- Energy-efficient servo motor systems