GKF 2500 | GKF 2500 L | GKF 2500 ASB IPK | GKF 2500 ASB 100% | GKF 3000
GKF 2500 – Capsule Filling Machine Packaging Technology
2 | GKF 2500 – Capsule Filling Machine
Modularity, Flexibility and Economical Operation in Capsule Filling 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
The GKF 2500 is a versatile and flexible
The GKF 2500 ASB IPK with in-process control
machine. This provides a high versatility of fill
provides you with weight control via statistical
options with varying product tapes. Even
evaluation, with documentation of the sample,
complex products with varying fill parameters
day, and batch data.
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.
Ergonomical and Secure Handling
Machine control via the touch-screen HMI is
With a focus on ergonomics and cleanability, our
especially -friendly. The control of the
engineers developed a machine that minimizes
machine and measurement data collection are
change-over and cleaning times and therefore
handled via an industrial PC. All production data
maximizes productivity. The cGMP-compliant
is also saved and managed on the industrial PC.
production cabin ensures easy accessibility and
The windows-based software complies with the
-friendly operation and cleaning. Likewise,
data security guidelines of 21 CFR part 11.
machine sub-assemblies are quickly and easily exchangeable, for example, during format
Quick and Easy Operation
change-overs.
The machine table-top is seamlessly machined as one piece. This allows for large-radius contours without undercuts, according to proper GMP design. Furthermore, only FDA-approved
GKF 2500 – Capsule Filling Machine | 3
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.
The GKF 2500 ASB 100% is equipped with an
The GKF 3000 is based on the successful
integrated checkweigher. Every capsule produced
GKF 2500 and sets a new benchmark in the
on the capsule is individually and precisely
pharmaceutical industry with its output of
weighed. Only capsules with a weight within
175,000 capsules per hour. This machine
the pre-set tolerances are accepted. Over- and
is reliable, low-maintenance, and provides
underweight capsules are rejected.
production security.
materials are used. The maintenance-free main
As the fastest tamping pin principle machine on
drive allows for quiet operation of the machine,
the market, the GKF 3000 offers precise dosing
reduces wear, and extends the machine lifetime.
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-
▶ Highly accurate dosing
cial seal separates the production and drive
▶ Simple operation
cabin, thereby protecting the product from
▶ cGMP-compliant design
foreign contaminants.
▶ Flexible dosing possibilities ▶ Low-maintenance operation ▶ Data security ▶ Reliability ▶ Optimal accessibility
4 | GKF 2500 – Capsule Filling Machine
Functional Description and Dosing Options Functional Description
2 1
3
12
4
11
5
10
6
9
7 8
1
Capsule orientation and separation
8
Open for optional pellet or tablet station
2
Capsule orientation and separation
9
Capsule closing with capsule body scanner (ASB function)
3
Capsule cap scanner (ASB function)
10 Individual capsule ejection (ASB function)
4
Open for an optional pellet station 1
11 Individual capsule ejection (ASB function)
Dosing station for powder/pellets via
12 Segment cleaning with compressed air (ASB function)
5
fixed or height-adjustable dosing disk, iquid filling station or micro-dosing station 6
Open for optical pellet station
7
F aulty-capsule rejection
No ASB function available on the GKF 3000
1 2
Not on the GKF 3000 Optional pellet station on the GKF 3000
GKF 2500 – Capsule Filling Machine | 5
Powder/Pellets Dosing station with patented slidegate technology for filling of powder or pellets.
Micro-dosing 1 Highly precise dosing of small powder volumes (e.g. Inhalation products).
Pellets The pellet station offers gentle filling and is ideally suited for use in combination filling.
Tablets 1/Micro-tablets 1 A defined number of tablets can be filled precisely via the tablet station
Liquids 1 The servo-controlled liquid pump offers the ideal filling technology for a broad viscosity spectrum.
Combinations Numerous product combination fills are possible on the GKF 2500-series thanks to its modular design.
1
Not on the GKF 3000
Custom Solutions The GKF 2500-series provides the opportunity to customize filling solutions, thanks to its open platform.
6 | GKF 2500 – Capsule Filling Machine
Optimal Productivity via Quality Control Reliable Operation via Automatic
infeed. A repeated missing capsule in a
Trouble-Shooting
particular segment bore is recognized by the
The automatic trouble-shooting feature auto-
consecutive fault function. Deformed capsules
mates your production and reduces your down-
in the capsule magazine are blown out via
time. The calibration strip in the empty capsule
individual compressed air lines and routed to
sorting magazine ensures that deformed or
a separate deformed capsule container.
damaged empty capsules are removed even before the filling station.
The capsule body scanner recognizes incomplete capsules during capsule closing. Therefore,
The mechanical capsule cap scanner determines
incomplete capsule portions do not make it into
if there are blockages in the empty capsule
the good capsule production container. The capsules that have been determined to be
ASB function
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 – Capsule Filling Machine | 7
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.
GKF 2500 ASB 100% with
fill weight. If a capsule is outside the tolerance
Online Weight Control
range, it is automatically rejected. The incident will then be documented in the production
Beyond the advantages of ASB, the integrated
report.
weighing system offers you a secure and documented production process. The highly accurate weight-control feature automatically controls fill weights with its
▶ Out-of-tolerance capsules are automatically rejected
pneumatic adjustment of the tamping pin
▶ Reduction of machine downtimes
pressure. Thereby, it is ensured that the
▶ Lights Out Operation
desired fill weight is maintained within the
▶ The capsule filling machine can be
specified tolerance range for the entire production process.
operated with or without the 100% checkweigher ▶ The checkweigher can be operated
The analysis software calculates an average fill weight from the checkweigher results and compares this average to the theoretical
with or without the capsule filler
8 | GKF 2500 – Capsule Filling Machine
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 predefined intervals. The sampling process can be completely defined by the . 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.
GKF 2500 – Capsule Filling Machine | 9
GKF 2500 with KKE 2500
Functional Description 100% Check Weighing
Accurate weighing method The Bosch patented “hanging weigh cell”
1
principle safely weighs all capsules while
2
avoiding dust or residue build up within the weighing cell. In addition the weigh cell design eliminates electrical interferences
3 4
such as electrostatic fields.
5
Dependable production documentation Data for the entire production run is stored and digitally evaluated by the friendly operating system. All of the data available
8
on the system can be saved on the integrated
7
6
1 Capsule Hopper
DVD Burner or transferred to an external
2
Insertion Pusher
system via the USB port.
3
Magazine
4 Calibration bar
Size changeover in < 1 min
9
5 Size Plate
The ergonomic design, which sucessfully
6 Separating Flaps
meets cGMP requirements permits a size
7 Transport Finger
changeover in less than one minute. All
10
change parts can be quickly disassembled
8
Weighing Cell
9 Transport Wheel
without tools, allowing rapid cleaning with
10 Discharge Flap
no residues.
Easy, fast cleaning Due 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.
10 | GKF 2500 – Capsule Filling Machine
Technical Data Machine cycles Max. 140 cycles/min. Electrical connection 400–440 V, +/- 10%, 50 Hz, 400–460 V, +/- 10%, 60 Hz 3 ph/PE Special voltages 10 kVA total
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
Maximum amperage 16A Vacuum pump electrical connection 1,85 kW, 50 Hz, 2,2 kW, 60 Hz Vacuum requirement 50 m3/h bei -250 mbar Utility Connections Compressed air supply Ø 13 mm Vacuum pump connection Ø 30 mm Dust collector connection 2 x Ø 70 mm Vacuum pump electrical connection Jogging cable connection Dust collector electrical connection Main electrical connection
1 2
optional on GKF 2500 and GKF 3000 Not on the GKF 3000
Formats Capsule format set for all standard capsule sizes, 00 to 5, D B Options High-adjustable dosing disk
2500
2500 ASB
Output (max. capsules/h)
150,000
Segment bores
18
Compressed air consumption (m³/h at 5 bar)
2
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
GKF 2500 / GKF 3000
2500 ASB IPK
150,000
Dust-collector electrical connection
2500 ASB 100%
3000
150,000
150,000
175,000
18
18
18
21
2
4
20
2
ca. 3,300
ca. 1,700
ca. 2,000
ca. 2,200
2762
2072
2027 2220
Accessories Vacuum pump for capsule separation Dust collector Automatic powder feeding Empty capsule feeder Capsule polisher Metal detector Distribution system
2466
GKF
Filling options: Powder filling station Pellet filling station Liquid filling station² Tablet filling station² Micro dosing station²
Infeeds Powder infeed – Triclamp DN 150, DIN 32676 Pellet/Tablet infeed – Triclamp DN 100, DIN 32676 Empty capsule infeed – Triclamp DN 100, DIN 32676
1389
2762
GKF 2500 – Capsule Filling Machine | 11
GKF 2500 ASB
2762
20272027 2027 20722072 2072
24662466 2466
2762 2762
2220
1389
2220 2220
1389 1389 2762
GKF 2500 ASB IPK
20272027 2027 20722072 2072
24662466 2466
2762 2762
2320
1389
2320 2320
1389 1389
2762
24662466 2466
2762 2762
20272027 2027 20722072 2072
23432343 2343
GKF 2500 ASB IPK 100%
3061 3061 3061
1389 1389 1389
Robert Bosch GmbH Packaging Technology Product Division Pharma Solid Stuttgarter Straße 130 71332 Waiblingen Phone +49 711 811-0 www.boschpackaging.com
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