Capsule Manufacturing & Packing System Solution in Bangalore, India | Insys Electrical

Capsule Manufacturing

Precision Automated Capsule Counting & Packaging

CAPSULE MANUFACTURING & PACKING

Project-Eight-Insys-Electrical

Application

Capsule counting & filling

Product

Genie NX PLC, Autonics Laser Sensor, Unison SSRs

Description

The machine is meant for filling capsules in bottles. Each machine have 2 sets of counting and filling section. For each section 30 capsules will fill in the bottle in 1.5 sec. after 3 sec again 30 capsules will fill to next bottle. This will continue in cycle & bottles will moves in conveyer to other section. But due to moisture capsules may be sticky and may not fall to the bottle. That bottle should detect & mark as less count one. For the counting laser sensor is used along with SSRs to give feed back to PLC. PLC will counts the capsules & if the count is not 30 PLC will trigger one hydraulic lever & takes out that bottle from the conveyer with warning.

Production Statistics

30

Capsules per Bottle

Target Count

1.5

Seconds Fill Time

Per Section

3

Seconds Cycle Time

Next Bottle

2

Filling Sections

Per Machine

Dual Section Layout

1

Section A

Capsule Count: 30 per bottle
Fill Time: 1.5 seconds
Laser Sensor: Autonics
2

Section B

Capsule Count: 30 per bottle
Fill Time: 1.5 seconds
Laser Sensor: Autonics

Quality Control Process

Capsule Drop
Laser Counting
PLC Verification
Count Check
Reject/Accept

If capsule count ≠ 30: Hydraulic lever removes bottle with warning signal

System Components

Genie NX PLC

Main Controller

Counting Logic

Autonics Sensor

Laser Detection

Capsule Counting

Unison SSRs

Signal Processing

PLC Feedback

Hydraulic Lever

Rejection System

Quality Control

Production Flow Cycle

Cycle Start
T=0s

Empty bottle positioned under filling section

Capsule Dispensing
T=1.5s

30 capsules dispensed into bottle

Laser Counting
Real-time

Autonics sensor counts falling capsules

PLC Verification
T=2s

Genie NX verifies count = 30 capsules

Quality Decision
T=2.5s

Accept (count=30) or Reject (count≠30)

Conveyor Move
T=3s

Bottle moves to next section or rejection

Technical Specifications

Production Parameters

Capsules per Bottle: 30 capsules
Fill Time: 1.5 seconds
Cycle Time: 3 seconds
Sections: 2 per Machine

Control System

Controller: Genie NX PLC
Counting Sensor: Autonics Laser
Signal Processing: Unison SSRs
Rejection System: Hydraulic Lever

Key Features

High-speed capsule counting
Precision laser detection
Automated quality control
Hydraulic rejection system
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