Production System

ロータリー式・シームレス式の2つの製法で、様々なニーズに最適なソフトカプセルを生産しています。We produce soft capsules ideal for any given need using rotary and seamless encapsulation methods.

Basic manufacturing principles

Basic principle of the rotary-type manufacturing method
The basic manufacturing principle of rotary-type soft capsules is to send two film sheets between two rotating die rolls while injecting the content liquid using an interlocked piston, and the dies perform pressured formation and cutting of capsules.
The film is heated to an ideal temperature by segmenting, resulting in perfectly adhered capsules by pressure and heat sealing.

Basic principle of the seamless-type manufacturing method
The basic manufacturing principle of seamless-type capsules is to cut a flow of double-layered liquid (outer: film liquid, inner: content liquid) at certain intervals. This results in the film liquid encasing the content liquid and formation of spherical capsules.

Rotary-type capsule production process

1. Film liquid preparation (preparation)
2. Content liquid preparation (mixing)

[Film liquid preparation]
The homogeneity of liquid and absence of bubbles are confirmed visually. Using the specification value of viscosity, the film liquid can be prepared to always have the same quality.
[Content liquid preparation]
Raw materials that have passed tests are accurately weighed and preparation is carried out according to procedure manuals, enabling production of high quality content liquid.

4. UV printing

[UV printing]
Capsules are clearly printed by irradiating UV laser on the surface. After printing, defective capsules are eliminated by an imaging inspection machine.

2. Filling

[Filling]
Film sheets are sent into between two die rolls, the content liquid is injected using a pump at the time of pressure cutting of sheets by the dies, the pressure cut sheets are heat sealed, making perfectly adhered capsules. Use of piston pump enables manufacturing of high quality capsules possessing the same amount of content liquid.

5. Packaging

[PTP/ pillow]
We installed PTP packaging machine that uses plug forming.
The line is equipped with imaging inspection machines for two positions, one is after supplying capsules into PTP pockets and another after aluminum adhesion.
Pillow packaging machine enables automatic supply of PTP sheets in the numbers of 1, 2, 3, 4, 6 or 10 sheets.

3. Sorting (Imaging inspection machine)
3. Sorting (Visual inspection)

[Imaging inspection]
By rotating soft capsules and using an imaging inspection machine with multiple cameras, capsules are sorted by imaging the entire circumference.
[Visual inspection]
Skilled inspectors perform visual inspection for all capsules.

6. Testing

[Testing]
The quality of preparation is assured by testing at each manufacturing process and the final product testing.

Seamless-type capsule production process

1. Film liquid preparation (preparation)
2. Content liquid preparation (mixing)

[Film liquid preparation]
The homogeneity of liquid and absence of bubbles are confirmed visually. Using the specification value of viscosity, the film liquid can be prepared to always possess the same quality.
[Content liquid preparation]
Raw materials that have passed tests are accurately weighed and preparation is carried out according to procedure manuals, enabling production of high quality content liquid.

5. Size sorting

[Size sorting]
Defective capsules with wrong sizes are accurately eliminated by flowing the capsules in a line.

2. Filling

[Filling]
By dripping and giving vibration at certain intervals using a pump with no pulsating flow, preparation with high filling accuracy and content uniformity is obtained.

6. Sorting (Imaging inspection machine)

[Sorting]
Highly reliable inspection system by rotating capsules and using multiple high-resolution cameras.

3. Drying

[Drying]
Capsules are evenly dried under low humidity and program-controlled temperatures.

7. Bulk packaging

[Bulk packaging]
Bulk packaging is performed using an automated box making and sealing machine.

4. Sifting

[Sifting]
Defective capsules with wrong sizes are eliminated by changing the mesh size, obtaining capsules with a uniform size.

8. Testing

[Testing]
The quality of preparation is assured by testing at each manufacturing process and final product testing.