High-Capacity Production Solution for Pharmaceutical, Nutraceutical & Cosmetic Softgels
I. Development Background
The JL-250II is an advanced system engineered for large-scale softgel manufacturing. With a single-unit annual production capacity exceeding 400 million capsules (based on 24/7 operation), it features a compact design, stable performance, and energy-efficient operation-making it the ideal choice for pharmaceutical, nutraceutical, and cosmetic industries. It serves as a reliable asset for producing high-quality softgels with consistent precision.
II. Target Applications
Core Industries Served
· Pharmaceuticals: Oral therapeutic softgels (e.g., fish oil, CoQ10)
· Nutraceuticals: Vitamin supplements, omega-3 capsules, herbal extract capsules
· Cosmetics: Serum capsules, moisturizing beads, active ingredient delivery systems
Material Compatibility
Supports diverse fill materials: oils, suspensions, pastes, and semi-solid formulations
III. Technical Specifications
Item | Parameters |
Die Roll Speed | 0–6 rpm |
Die Roll Specification | φ150×250mm (aircraft-grade 7075-T6 aluminum alloy, 20% higher strength-to-weight ratio than standard alloys) |
Capsule Output | 120,000 capsules/hour (8mm ovoid shape, 450mg fill weight at 4rpm die roll speed) |
Filling Precision | >±0.1% (industry-leading consistency for fill weight control) |
Material Dosage Range | 0–2mL (adjustable for micro to macro capsule sizes) |
Machine Weight | 1,400 kg |
Dimensions | 2040×960×1900 (H) mm |
IV. Key Advantages
1. Intelligent Control & Connectivity
· 15-inch Touchscreen: Integrates real-time fault diagnosis, stores 100+ formulations, and includes a reserved Ethernet port for Industry 4.0 remote monitoring and data analytics.
· Independent VFD Motor Control: Die roll axis, casting drum, and calender roller are driven by separate variable-frequency drives, enabling precise speed synchronization and intuitive HMI adjustments.
2. Mechanical Durability & Efficiency
· Aviation-Grade Die Rolls: Constructed from 7075-T6 aluminum alloy (used in aerospace structures), these rolls resist wear and corrosion, offering a service life of over 10,000 production hours (30% longer than steel alternatives).
· Optimized Cavity Design: Proprietary die pattern increases capsule density by 12%, reducing gelatin consumption by 15% compared to standard designs while ensuring uniform seal quality.
· Parallel Alignment System: Horizontal alignment of the gelatin casting drum, lubricating oil roller, and die rolls minimizes vibration (tested <0.5g at 6rpm), providing 20% better stability than competing models.
3. Energy & Material Savings
· Micro-Lubrication Technology: A nozzle system applies a 0.01mm-thick food-grade lubricant film to gelatin ribbons, eliminating post-production cleaning and reducing consumable waste by 40%.
· Temperature-Controlled Casting Drum: Antifreeze-circulated drum with air conditioner precision (±0.5°C) cuts energy use by 25% versus direct-heat systems, with 30% faster gelatin film solidification.
4. Quality Assurance Design
· Stainless Steel Fluidized Pre-Drying: 316L stainless steel mesh directing plates with bottom-up cool air flow (15m/s velocity) ensure uniform pre-drying, achieving <1% capsule deformation rate and a 25% glossier surface finish.
· Friction-Free Drying (Optional): Fluid-bed technology in the tumble dryer suspends capsules, eliminating abrasion and protecting delicate formulations (e.g., essential oil capsules) from seal damage.
5. Versatile Material Handling
· Heated & Agitated Hopper: 3-zone heating (30–70°C, ±1°C control) and dual-blade mixing maintain pumpable consistency for paste-like materials (e.g., beeswax-based cosmetics), reducing downtime from clogs.
· Homogenization Option: Bottom-mounted rotor-stator head (optional) processes particles up to 500μm, ensuring uniform suspension for formulations like sunscreen capsules with titanium dioxide pigments.
V. Supporting Equipment
1. Gelatin Melting Tank
· Tri-Layer Construction: Stainless steel inner layer, heating jacket, and insulation layer, 500L capacity.
· Smart Melting: Top-mounted agitator (15–30rpm) and vacuum system (≤-0.09MPa) ensure bubble-free melt; compressed air transfer (0.4–0.6MPa) delivers liquid gelatin to the service tank.
2. Material Mixing & Preparation Tank
· Flexible Sizing: Available in 100–1000L, with optional CIP/SIP compatibility for sanitary cleaning.
· Homogenization Function: Bottom-mounted homogenizer head (2000rpm max) disperses particles, ideal for suspension-based fill materials.
3. Tumble Dryer
· Fluidized-Bed Technology: 500m³/h airflow fluidizes capsules, achieving 90% moisture reduction in 45 minutes-50% faster than static drying-with zero surface abrasion.
· Gentle Drying: Protects sensitive ingredients (e.g., probiotic capsules) through contact-free drying.
VI. Customer Value Proposition
Three Core Benefits
1. High Efficiency: 120,000 capsules/hour output with quick die roll changeovers (≤30 minutes), enabling flexible multi-SKU production.
2. Cost Optimization: 20% lower energy consumption, 15% less gelatin waste, and 30% reduced labor costs from no-clean capsules.
3. Quality Assurance: ±0.1% filling precision, aviation-grade durability, and a 3-year warranty on critical components for GMP/ISO 13485 compliance.
Ideal For
· Large-scale production lines (1+ billion capsules/year)
· Multi-formula pilot runs (supports rapid tooling changes)
· Regulated environments requiring strict quality control
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