gkf 2500 – capsule filling machine

Packaging Technology

GKF 2500 – Capsule Filling MachineGKF 2500 | GKF 2500 L | GKF 2500 ASB IPK | GKF 2500 ASB 100% | GKF 3000

2 | GKF 2500 – Capsule Filling Machine

Modularity, Flexibility and Economical Operation in Capsule Filling

Ergonomical and Secure HandlingWith a focus on ergonomics and cleanability, our engineers developed a machine that minimizes change-over and cleaning times and therefore maximizes productivity. The cGMP-compliant production cabin ensures easy accessibility and user-friendly operation and cleaning. Likewise, machine sub-assemblies are quickly and easily exchangeable, for example, during format change-overs.

Machine control via the touch-screen HMI is especially user-friendly. The control of the machine and measurement data collection are handled via an industrial PC. All production data is also saved and managed on the industrial PC. The windows-based software complies with the data security guidelines of 21 CFR part 11.

Quick and Easy OperationThe machine table-top is seamlessly machined as one piece. This allows for large-radius con-tours without undercuts, according to proper GMP design. Furthermore, only FDA-approved

The GKF 2500 is a versatile and flexible machine. This provides a high versatility of fill options with varying product tapes. Even complex products with varying fill parameters can easily be processed. Thanks to the modular design of this capsule filler, the machine can be changed-over in a minimal amount of time.

The GKF 2500 ASB IPK with in-process control provides you with weight control via statistical evaluation, with documentation of the sample, day, and batch data.

Whichever products you would like to fill – powders, pellets, tablets, liquids, micro-dosing or combinations, the GKF 2500 offers the correct solution in the high speed production range

GKF 2500 – Capsule Filling Machine | 3

materials are used. The maintenance-free main drive allows for quiet operation of the machine, reduces wear, and extends the machine lifetime.

The GKF 3000 is based on the successful GKF 2500 and sets a new benchmark in the pharmaceutical industry with its output of 175,000 capsules per hour. This machine is reliable, low-maintenance, and provides production security.

The GKF 2500 ASB 100% is equipped with an integrated checkweigher. Every capsule produced on the capsule is individually and precisely weighed. Only capsules with a weight within the pre-set tolerances are accepted. Over- and underweight capsules are rejected.

As the fastest tamping pin principle machine on the market, the GKF 3000 offers precise dosing with minimal product loss. Powder or pellet products are gently filled and even products with varying fill parameters can be optimally filled via height-adjustable dosing disks. A spe-cial seal separates the production and drive cabin, thereby protecting the product from foreign contaminants.

The design of this capsule filler provides for quick and complete cleaning, as well as efficient change-overs. Thereby, the machine fulfills all modern cGMP requirements. The PC-based control system also allows for automatic data-logging of all production processes. Therefore, the GKF 2500 sets new standards in pharmaceutical security.

▶ Highly accurate dosing▶ Simple operation▶ cGMP-compliant design▶ Flexible dosing possibilities▶ Low-maintenance operation▶ Data security▶ Reliability▶ Optimal accessibility


Functional Description

Capsule orientation and separation

Capsule orientation and separation

Capsule cap scanner (ASB function)

Open for an optional pellet station 1

Dosing station for powder/pellets via fixed or height-adjustable dosing disk, iquid filling station or micro-dosing station

Open for optical pellet station

Faulty-capsule rejection

Open for optional pellet or tablet station

Capsule closing with capsule body scanner (ASB function)

Individual capsule ejection (ASB function)

Individual capsule ejection (ASB function)

Segment cleaning with compressed air (ASB function)

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Functional Description and Dosing Options

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No ASB function available on the GKF 3000 1 Not on the GKF 30002 Optional pellet station on the GKF 3000


Powder/Pellets Dosing station with patented slidegate technology for filling of powder or pellets.

Micro-dosing 1Highly precise dosing of small powder volumes (e.g. Inhalation products).

PelletsThe pellet station offers gentle filling and is ideally suited for use in combination filling.

Tablets 1/Micro-tablets 1A defined number of tablets can be filled precisely via the tablet station

Liquids 1The servo-controlled liquid pump offers the ideal filling technology for a broad viscosity spectrum.

Custom SolutionsThe GKF 2500-series provides the opportunity to customize filling solutions, thanks to its open platform.

CombinationsNumerous product combination fills are possible on the GKF 2500-series thanks to its modular design.

1 Not on the GKF 3000


Optimal Productivity via Quality Control

Reliable Operation via Automatic Trouble-Shooting The automatic trouble-shooting feature auto- mates your production and reduces your down-time. The calibration strip in the empty capsule sorting magazine ensures that deformed or damaged empty capsules are removed even before the filling station.

The mechanical capsule cap scanner determines if there are blockages in the empty capsule

ASB function

infeed. A repeated missing capsule in a particular segment bore is recognized by the consecutive fault function. Deformed capsules in the capsule magazine are blown out via individual compressed air lines and routed to a separate deformed capsule container.

The capsule body scanner recognizes incomplete capsules during capsule closing. Therefore, incomplete capsule portions do not make it into the good capsule production container.

The capsules that have been determined to be faulty are individually rejected at the 18 capsule ejection flaps. The segment cleaning station with compressed air nozzles loosens sticky products and capsule fragments from the segment bores and reliably vacuums them away. This station ensures the cleaning of all the segments for the next filling cycle.


GKF 2500 ASB 100% with Online Weight Control

Beyond the advantages of ASB, the integrated weighing system offers you a secure and documented production process.

The highly accurate weight-control feature automatically controls fill weights with its pneumatic adjustment of the tamping pin pressure. Thereby, it is ensured that the desired fill weight is maintained within the specified tolerance range for the entire production process.

The analysis software calculates an average fill weight from the checkweigher results and compares this average to the theoretical

The GKF 2500-series guarantees optimal productivity and pharmaceutical security in capsule filling with it’s automatic trouble-shooting features (ASB), in the GKF 2500 ASB, GKF 2500 ASB IPK or GKF 2500 ASB 100% versions.

fill weight. If a capsule is outside the tolerance range, it is automatically rejected. The incident will then be documented in the production report.

▶ Out-of-tolerance capsules are automatically rejected

▶ Reduction of machine downtimes▶ Lights Out Operation▶ The capsule filling machine can be

operated with or without the 100% checkweigher

▶ The checkweigher can be operated with or without the capsule filler


No Risk – Weighing Technology of the Highest Quality

GKF 2500 ASB IPK with In-Process Control Filled capsule samples are individually removed from the filling process and weighed at pre- defined intervals. The sampling process can be completely defined by the user. The analysis software calculates an average fill weight from the checkweigher results and compares this average to the theoretical fill weight. If the average weight of several samples exceeds the tolerance limit, the tamping pin pressure is automatically adjusted by the pneumatic tamping pin adjustment function. The incident will then be documented in the production report.

After the sample capsules are weighed they are collected in a separate container. The individual weights are indexed according to their position in the segment. The scale will tare itself after every capsule it weighs.


Accurate weighing methodThe Bosch patented “hanging weigh cell” principle safely weighs all capsules while avoiding dust or residue build up within the weighing cell. In addition the weigh cell design eliminates electrical interferences such as electrostatic fields.

Dependable production documentationData for the entire production run is stored and digitally evaluated by the user friendly operating system. All of the data available on the system can be saved on the integrated DVD Burner or transferred to an external system via the USB port.

Size changeover in < 1 minThe ergonomic design, which sucessfully meets cGMP requirements permits a size changeover in less than one minute. All change parts can be quickly disassembled without tools, allowing rapid cleaning with no residues.

Functional Description 100% Check Weighing

Capsule Hopper

Insertion Pusher

Magazine

Calibration bar

Size Plate

Separating Flaps

Transport Finger

Weighing Cell

Transport Wheel

Discharge Flap

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Easy, fast cleaningDue to the hermetic separation of the production and drive section (balcony design) there is no contamination of the product and the machine is easy to clean.

Standard automatic trouble shooting (ASB)The ASB function automatically detects and ejects deformed capsules, helping to eliminate unnecessary downtime and increase productivity.

GKF 2500 with KKE 2500


Technical DataMachine cyclesMax. 140 cycles/min.

Electrical connection 400–440 V, +/- 10%, 50 Hz, 400–460 V, +/- 10%, 60 Hz 3 ph/PESpecial voltages10 kVA total

Maximum amperage16A

Vacuum pump electrical connection1,85 kW, 50 Hz, 2,2 kW, 60 Hz

Vacuum requirement 50 m3/h bei -250 mbar

Utility Connections Compressed air supply Ø 13 mmVacuum pump connection Ø 30 mmDust collector connection 2 x Ø 70 mmVacuum pump electrical connectionJogging cable connectionDust collector electrical connectionMain electrical connection

2500 ASB 2500 ASB IPK 2500 ASB 100% 30002500GKF

Infeeds Powder infeed – Triclamp DN 150, DIN 32676Pellet/Tablet infeed – Triclamp DN 100, DIN 32676Empty capsule infeed – Triclamp DN 100, DIN 32676

Standard equipment Base machine with integrated electrical

cabinet and built-in HMI Machine control: industrial-PC Empty capsule hopper with minimum

and maximum level control sensors Adjustment of the dosing disk height Capsule closing station with concave

closing pins Cleaning station with compressed air

nozzles and vacuum suction

Formats Capsule format set for all standard

capsule sizes, 00 to 5, D B

OptionsHigh-adjustable dosing disk

Filling options:Powder filling stationPellet filling station Liquid filling station²Tablet filling station²Micro dosing station²

AccessoriesVacuum pump for capsule separationDust collectorAutomatic powder feedingEmpty capsule feederCapsule polisherMetal detectorDistribution system

1 optional on GKF 2500 and GKF 30002 Not on the GKF 3000

GKF 2500 / GKF 3000

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2762

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Output (max. capsules/h) 150,000 150,000 150,000 150,000 175,000

Segment bores 18 18 18 18 21

Compressed air consumption (m³/h at 5 bar) 2 2 4 20 2

Dust-collector electrical connection 200 | 220 | 380 | 400 V 50 Hz, 2 x 2,2 kW

220 | 380 | 400 | 460 | 480 V 60 Hz, 2 x 2,55 kW

Dust-collector air flow volume 20 m³/min, open suction

Weight (kg) ca. 1,700 ca. 2,000 ca. 2,200 ca. 3,300 ca. 1,700


2343

2072

1389

2466

2762

1389

2466

2762

2072

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2072

1389

2466

2762

3061

2027

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2027

2343

2072

1389

2466

2762

1389

2466

2762

2072

2320

2220

2072

1389

2466

2762

3061

2027

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GKF 2500 ASB

GKF 2500 ASB IPK

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2072

1389

2466

2762

1389

2466

2762

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2320

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1389

2466

2762

3061

2027

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GKF 2500 ASB IPK 100%

Robert Bosch GmbH Packaging Technology Product Division Pharma Solid

Stuttgarter Straße 130 71332 Waiblingen Germany Phone +49 711 811-0 www.boschpackaging.com [email protected]

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gkf 2500 – capsule filling machine

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