Every year, our team at Vitaquest manufactures over one billion capsules in our world-class facilities. These billion doses go through a rigorous manufacturing, quality control, and packaging process, all to ensure you and your customers receive the highest-quality products available in the nutraceutical industry. This is no easy task. It takes the perfect combination of people, infrastructure, and ingenuity to succeed in the highly competitive market that Vitaquest operates in. This is why we continuously strive to Deliver What’s Next through state-of-the-art infrastructure and equipment. As part of this effort, we are pleased to announce the installation of a new KLS Capsule Filling Machine in our 100 Jefferson facility.
What Are the Steps in the Capsule Filling Process?
The nutraceutical capsule filling process typically begins by preparing the capsule shells. The shells, often made of gelatin or vegetable-based materials, are carefully inspected, and sorted to ensure their quality.
Once the capsule shells are ready, our scientists formulate and blend the ingredients. This process involves carefully measuring and combining the desired quantities of active ingredients, excipients, and fillers according to the specific formulation. The blended mixture is thoroughly combined to ensure uniform distribution of the ingredients.
Then the filling process begins. This is where our new KLS Capsule Filling Machine comes in! During this process, the machine dispenses the formulated mixture into the empty capsule shells one-by-one.
All of the following must be considered carefully when using a capsule filling machine:
- The accuracy of ingredient measurement and blending.This is crucial to ensure consistent potency and quality across the capsules. Any variation in the formulation or blending process can lead to inconsistent dosing.
- The performance and calibration of the capsule filling machine.This is essential for precise and efficient filling. Regular maintenance and monitoring are necessary to prevent errors or breakdowns that can disrupt production.
- Proper handling and storage of the filled capsules.This is an important step to ensure the capsules maintain their integrity and prevent contamination until they are packaged and distributed.
What does the new KLS machine offer Vitaquest and our customers? This high-speed, tamping-style machine can operate with a maximum production rate of 225,000 capsules per hour—doubling the rate of our older Index machines and providing the increased production rates required to meet the growing demands of our customer base. The main motor, indexing drives, and vacuum pump are robust and durable, with the machine itself featuring time-saving mechanical designs to ensure easy maintenance and quick changeovers.
This capsule filling machine also features:
- An intuitive touch-screen layout
- A 2-hand remote jog controller
- Safety interlocks
Combining improved safety features with a user-friendly control system and the ability to run efficiently at higher speeds, this machine represents the latest in capsule filling technology and will provide years of dependable service to our company. It joins our collection of other state-of-the-art technologies and systems, including our KLS capsule polisher and capsule inspection machine.
Committed to Innovation
Why do we continue to invest in new technology? Because we are all motivated by a commitment to a common goal: to Deliver What’s Next to our customers and demonstrate why our company has continued to succeed and grow over its rich history.
We look forward to sharing the many benefits of this new capsule filling machine and our other innovations with our customers. Stay tuned for more to come!
If you’re looking for a capsule manufacturer who is dedicated to innovation, quality, and customer service, we encourage you to contact Vitaquest. Call 800-526-9095 to speak with one of our knowledgeable sales executives or request a free capsule manufacturing price quote.