Dry syrup filling machines with automatic capping systems are a vital part of modern pharmaceutical production lines, designed to fill powder or granular formulations into bottles with precision, hygiene, and efficiency. These machines integrate accurate dosing technology with automatic sealing and capping systems, ensuring that every container is securely closed to maintain product stability and shelf life.
At TOPTEC PVT. LTD, our dry syrup fillers are engineered to deliver high output speeds, exceptional dosing accuracy, and compliance with GMP, FDA, and WHO guidelines, making them ideal for both large-scale and medium-scale manufacturing facilities.
Working Principle of Dry Syrup Filling Machines with Automatic Capping
1. Bottle Feeding System
- Automatic bottle unscramblers or conveyors feed empty bottles into the filling station.
- Bottles are aligned and spaced correctly using indexing systems.
2. Powder Feeding and Dosing
- Auger-based filling systems measure the exact quantity of dry syrup powder.
- Advanced servo motors control the auger to maintain ±1% accuracy.
- Product contact parts are made from SS316L stainless steel for hygiene and durability.
3. Powder Settling and Dust Control
- Vibratory settling systems ensure even distribution of powder inside the bottle.
- Integrated dust extraction systems maintain a clean production environment.
4. Automatic Capping System
- Caps are fed via an automatic cap elevator or vibratory bowl feeder.
- Capping heads apply consistent torque for tight sealing, preventing leakage or contamination.
- Different cap types (screw caps, pilfer-proof caps, CRC caps) can be handled.
5. Output and Discharge
- Capped bottles are transferred to the labeling section or collected for secondary packaging.
Key Features of Dry Syrup Filling Machines with Automatic Capping Systems
1. High Precision Dosing
- Servo-controlled auger fillers ensure consistent fill weights.
- Accuracy is maintained even with variable bulk density powders.
2. Hygienic and Contamination-Free Operation
- Enclosed filling stations with laminar airflow (optional) for sterile production.
- Dust extraction systems to prevent airborne contamination.
3. Rapid Changeover Capability
- Quick adjustments for different bottle sizes and fill weights without extensive downtime.
4. Advanced Control Systems
- PLC with HMI interface for setting parameters, alarms, and monitoring production data.
5. Compliance with International Standards
Advantages of Using Dry Syrup Fillers with Automatic Capping
- Increased production efficiency due to high-speed automation.
- Reduced labor costs by eliminating manual filling and capping.
- Consistent product quality due to precise dosing and sealing.
- Improved hygiene and safety through enclosed operations.
- Minimal downtime due to quick changeovers and robust design.
Technical Specifications (Typical Model)
| Specification | Details |
|---|---|
| Output Capacity | 60–120 bottles/min |
| Filling Range | 5g – 100g |
| Filling Accuracy | ±1% |
| Bottle Diameter | 25–100 mm |
| Bottle Height | 50–200 mm |
| Cap Types | Screw cap, CRC, pilfer-proof |
| Control System | PLC + HMI |
| Power Requirement | 3 Phase, 415V, 50Hz |
| Compliance | cGMP, WHO, FDA |
Maintenance of Dry Syrup Filling and Capping Machines
Daily Maintenance
- Clean hopper, auger, and nozzles after each production cycle.
- Inspect capping heads for dust buildup and torque accuracy.
Weekly Maintenance
- Lubricate moving parts with food-grade lubricants.
- Inspect seals, gaskets, and auger drive assemblies for wear.
Monthly Maintenance
- Check PLC calibration for dosing accuracy.
- Inspect cap feeding systems for alignment and smooth operation.
Common Issues and Troubleshooting
1. Inconsistent Powder Fill
- Cause: Worn auger or improper calibration
- Solution: Replace or recalibrate auger and servo system
2. Poor Cap Sealing
- Cause: Incorrect torque settings or damaged capping head
- Solution: Adjust torque, replace worn capping components
3. Dust Leakage
- Cause: Faulty dust extraction system
- Solution: Inspect and replace filters and suction pipes
Integration with Packaging Lines
Dry syrup filling machines with automatic capping systems can be integrated with:
- Automatic labeling machines for product identification.
- Shrink wrapping and carton packing machines for secondary packaging.
- Serialization and vision inspection systems for regulatory compliance.
Applications of Dry Syrup Filling and Capping Systems
- Pharmaceutical Industry: Antibiotics, probiotics, pediatric formulations
- Nutraceutical Industry: Health supplements, protein powders
- Food Industry: Powdered food ingredients, flavoring powders
Why Choose TOPTEC PVT. LTD for Dry Syrup Filling Solutions
At TOPTEC PVT. LTD, we specialize in dry syrup filling machines with integrated automatic capping systems designed for efficiency, compliance, and long-term performance. Our solutions offer:
- Customizable configurations for varying bottle sizes and production speeds.
- Stainless steel construction for superior hygiene.
- Reliable after-sales support with training, spare parts, and service.
Dry syrup filling machines with automatic capping systems are essential for high-speed, hygienic, and precise pharmaceutical production. With proper setup, maintenance, and operation, these systems ensure maximum output, consistent quality, and regulatory compliance. Choosing a trusted manufacturer like TOPTEC PVT. LTD guarantees high performance, long service life, and cost-effective production.
Dry Syrup Filling Machines for Pharmaceutical Applications
Dry syrup filling machines are an essential part of modern pharmaceutical manufacturing, specifically designed for powder-based medications that are reconstituted with liquid before consumption. These machines provide high precision, sterile filling, and automated sealing, ensuring every product meets GMP, FDA, and WHO standards.
At TOPTEC PVT. LTD, we manufacture advanced dry syrup filling machines engineered for accuracy, speed, and compliance, making them the preferred choice for pharmaceutical production lines worldwide.
Working Principle of Dry Syrup Filling Machines
1. Bottle Feeding and Orientation
- Empty bottles are fed automatically using bottle unscramblers or conveyors.
- Indexing mechanisms position bottles for accurate filling.
2. Powder Feeding and Dosing
- Servo-driven auger fillers measure precise powder quantities.
- Hopper agitators prevent clumping and ensure consistent powder flow.
3. Powder Settling and Dust Control
- Vibration systems help powder settle evenly in bottles.
- Integrated dust extraction systems maintain a clean working environment.
4. Sealing and Capping
- Bottles are sealed with aluminum or plastic caps using automatic capping systems.
- Torque settings ensure leak-proof closure.
5. Discharge and Packaging
- Finished bottles are transferred to the labeling and secondary packaging lines.
Key Features of Pharmaceutical Dry Syrup Filling Machines
1. High Accuracy and Consistency
- Servo motor-controlled auger fillers ensure ±1% filling accuracy.
- Automatic weight adjustment maintains consistency across batches.
2. Sterile and Hygienic Operation
- SS316L stainless steel contact parts ensure contamination-free production.
- Option for laminar airflow systems to maintain sterility.
3. High-Speed Output
- Capable of producing 60–120 bottles per minute, depending on product specifications.
4. Advanced Control System
- PLC with HMI for easy operation, data logging, and alarm management.
5. Compliance with Global Standards
- Fully compliant with cGMP, FDA, WHO, and CE certifications.
Applications in Pharmaceutical Industry
- Antibiotics: Amoxicillin, Cefixime, Azithromycin dry suspensions
- Pediatric Medicines: Vitamin and mineral syrups in powder form
- Probiotics and Nutraceuticals: Powder-based health supplements
- Custom Formulations: Specialized dry suspensions for chronic treatments
Advantages of Dry Syrup Filling Machines in Pharmaceuticals
- Consistent dosing accuracy for patient safety
- Increased production efficiency due to full automation
- Reduced contamination risks through enclosed operation
- Minimal downtime thanks to quick changeover design
- Lower labor costs by eliminating manual filling and capping
Technical Specifications (Standard Model)
| Specification | Details |
|---|---|
| Output Capacity | 60–120 bottles/min |
| Filling Range | 5g – 100g |
| Filling Accuracy | ±1% |
| Bottle Diameter | 25–100 mm |
| Bottle Height | 50–200 mm |
| Cap Types | Screw cap, CRC, pilfer-proof |
| Control System | PLC + HMI |
| Power Requirement | 3 Phase, 415V, 50Hz |
| Compliance | cGMP, WHO, FDA |
Maintenance for Pharmaceutical Dry Syrup Filling Machines
Daily Maintenance
- Clean hopper, auger, and contact parts after every batch.
- Inspect capping heads for torque consistency.
Weekly Maintenance
- Lubricate moving parts with food-grade lubricants.
- Check O-rings, seals, and auger components for wear.
Monthly Maintenance
- Recalibrate PLC parameters for dosing accuracy.
- Inspect cap feeder systems for smooth operation.
Common Issues and Troubleshooting
1. Inconsistent Fill Weight
- Cause: Worn auger or calibration error
- Solution: Replace auger or recalibrate system
2. Powder Leakage
- Cause: Dust extraction malfunction
- Solution: Inspect and replace filters
3. Loose Caps
- Cause: Incorrect torque settings
- Solution: Adjust torque and inspect capping heads
Integration with Pharmaceutical Packaging Lines
Dry syrup filling machines can be seamlessly integrated with:
- Labeling machines for compliant product identification
- Cartoning and shrink-wrapping machines for secondary packaging
- Vision inspection systems for serialization and batch verification
Why Choose TOPTEC PVT. LTD for Pharmaceutical Dry Syrup Filling Solutions
At TOPTEC PVT. LTD, we deliver customized dry syrup filling solutions that meet the most stringent pharmaceutical industry requirements. Our systems offer:
- Precise dosing technology for consistent results
- Robust stainless steel design for long service life
- Comprehensive after-sales support, including training and spare parts
Dry syrup filling machines for pharmaceutical applications are essential for high-speed, hygienic, and accurate production of powder-based medications. With proper installation, calibration, and maintenance, these systems ensure regulatory compliance, patient safety, and optimal production efficiency. Choosing a trusted manufacturer like TOPTEC PVT. LTD guarantees reliable performance and long-term value for your production line.
How to Maintain a Dry Syrup Filling Machine?
Dry syrup filling machines are critical for the accurate, hygienic, and efficient packaging of pharmaceutical powders. Regular and precise maintenance routines are essential to ensure continuous operation, minimal downtime, and long service life. A well-maintained machine not only guarantees consistent fill weights but also ensures compliance with GMP, FDA, and WHO standards.
At TOPTEC PVT. LTD, we design our dry syrup filling machines for durability, but we strongly recommend following a structured maintenance schedule to optimize performance.
Daily Maintenance of Dry Syrup Filling Machines
1. Cleaning of Contact Parts
- Remove and clean the hopper, auger, dosing system, and nozzles after each production cycle.
- Use compressed air and approved cleaning solutions to eliminate powder residue.
2. Visual Inspection
- Inspect bottle feed conveyor, auger drive, and capping heads for visible wear or misalignment.
- Check for loose fasteners and tighten if required.
3. Dust Extraction System Check
- Ensure dust collectors and filters are operational to prevent contamination.
- Empty dust collection bins regularly.
Weekly Maintenance of Dry Syrup Filling Machines
1. Lubrication of Moving Parts
- Apply food-grade lubricants to bearings, chains, and gear assemblies.
- Avoid over-lubrication to prevent contamination of the product zone.
2. Calibration Verification
- Check the auger fill weight accuracy using test runs.
- Adjust PLC parameters if variations are detected.
3. Capping Unit Maintenance
- Inspect torque settings on capping heads.
- Clean the cap feeding bowl to ensure smooth operation.
Monthly Maintenance of Dry Syrup Filling Machines
1. Detailed Mechanical Inspection
- Examine auger flights, hopper walls, and sealing gaskets for signs of wear.
- Replace damaged or worn parts to avoid downtime during production.
2. Electrical System Check
- Inspect PLC connections, servo drives, and HMI wiring for signs of wear or overheating.
- Test all sensors and switches for proper functioning.
3. Conveyor and Bottle Indexing System
- Check belt tension and adjust if needed.
- Inspect bottle indexing star wheels or pucks for alignment.
Quarterly and Annual Maintenance
1. Complete Calibration
- Perform a full calibration of the filling system to restore original accuracy.
- Validate the machine performance using certified test weights.
2. Overhaul of Critical Components
- Replace seals, bearings, auger shafts, and capper spindles as part of preventive maintenance.
- Conduct a comprehensive inspection of servo motors and replace worn parts.
3. Validation and Compliance Testing
- Conduct GMP validation protocols to ensure compliance.
- Document all maintenance activities for audit purposes.
Cleaning and Sterilization Best Practices
1. Clean-in-Place (CIP) Systems
- Use automated CIP systems to clean contact parts without dismantling.
- Ensure that CIP cycles meet regulatory cleaning validation requirements.
2. Manual Cleaning for Critical Components
- Disassemble parts in contact with the product and clean manually with approved cleaning agents.
- Use non-abrasive brushes to avoid damaging stainless steel surfaces.
3. Sterilization
- Sterilize parts that come into contact with the powder, especially for antibiotic production lines.
Common Maintenance Mistakes to Avoid
- Skipping regular lubrication, leading to bearing wear.
- Delaying seal replacements, which can cause leakage.
- Neglecting calibration, resulting in inaccurate dosing.
- Improper cleaning, leading to cross-contamination.
Tips for Extending the Life of a Dry Syrup Filling Machine
- Use only OEM spare parts to maintain machine integrity.
- Maintain an inventory of critical spares like augers, seals, and bearings.
- Train operators on correct startup, shutdown, and cleaning procedures.
- Keep detailed maintenance logs for tracking machine performance.
Maintenance Schedule Summary Table
| Maintenance Task | Frequency |
|---|---|
| Cleaning of hopper & auger | Daily |
| Dust extraction check | Daily |
| Lubrication of moving parts | Weekly |
| Calibration check | Weekly |
| Capping unit inspection | Weekly |
| Detailed mechanical inspection | Monthly |
| Electrical system check | Monthly |
| Complete calibration | Quarterly/Annually |
| Overhaul of critical parts | Annually |
Conclusion
Maintaining a dry syrup filling machine is crucial for ensuring precision, hygiene, and uninterrupted production in pharmaceutical manufacturing. A structured maintenance plan—covering daily, weekly, monthly, and annual inspections—helps prevent breakdowns and extends the life of the equipment.
At TOPTEC PVT. LTD, our dry syrup filling machines are built for durability, but proper care ensures maximum performance, compliance, and cost efficiency over the long term.
Where to Find Capsule Filler Machine Replacement Parts?
