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YWJ250-IIIA(SERVO)+SGL70-I
The YWJ250-IIIA(SERVO)+SGL70-I integrated softgel production line combines a servo-driven encapsulation machine with a double-layer dehumidification rotary cage dryer, creating a continuous production system from gelatin encapsulation through controlled drying. Developed by Beijing Sinagel Technology, this integrated line reduces material transfer between encapsulation and drying stages, minimizing manual handling and potential capsule damage. The system is designed for medium to large scale softgel production in commercial manufacturing facilities.
The servo-driven YWJ250-IIIA encapsulation machine achieves production speeds up to 150,000 capsules per hour with improved motion control compared to mechanically driven models. The integrated SGL70-I double-layer dehumidification dryer provides continuous inline drying, reducing total drying cycle time compared to offline drying systems. The integrated connection between encapsulation machine and dryer uses food-grade flexible ducting, with automatic capsule transfer without manual collection and loading.
Both units use 304 stainless steel construction for all product contact surfaces, meeting GMP requirements for pharmaceutical production. The dryer cabinet features double-wall insulation with polyurethane foam core to maintain stable internal temperature and reduce energy loss. Rotary cages are constructed from perforated 304 stainless steel with polished surfaces to prevent capsule sticking and facilitate cleaning. The entire line is mounted on lockable casters for position adjustment during installation and maintenance.
The servo drive system on the YWJ250-IIIA provides independent control of die roll rotation, injection pump timing, and gelatin feed, improving synchronization accuracy to within 0.1 degrees of rotation. The dehumidification system on the SGL70-I removes moisture from process air, maintaining consistent drying conditions regardless of ambient humidity in the production facility. Each dryer section can be set to independent rotation direction and speed, allowing staged drying profiles that reduce capsule deformation during the critical initial drying period.
The complete production line requires a 380V three-phase power supply with 80A dedicated circuit. Compressed air should be oil-free and filtered, supplied at 0.6-0.8 MPa with minimum 0.5 m³/minute flow rate. Chilled water at 7-12°C is required for both the encapsulation machine cooling circuit and the dehumidification system condenser, with total flow rate of 25 L/minute. Installation requires a level concrete floor with minimum 1.5 meter clearance along both sides of the line for maintenance access.
The entire production line uses a centralized PLC control system with two touchscreen HMI panels—one at the encapsulation machine and one at the dryer discharge end. The system synchronizes encapsulation speed with dryer capacity, automatically adjusting production rate if drying conditions fall outside set parameters. All production data including output count, temperature, humidity, and running time are logged for batch records, supporting traceability requirements for pharmaceutical production.
The servo-driven encapsulation machine features an alignment-free die roll design, simplifying die changeover and reducing setup time between batches. The double-layer rotary cage design provides 60% more drying capacity compared to single-layer dryers of equivalent floor space. Capsules move sequentially through drying sections via internal transfer chutes, eliminating manual transfer between drying stages. The built-in dehumidification system removes moisture from recirculated air, maintaining low humidity even in facilities without dedicated environmental control.
All electrical components carry CE certification, with safety interlocks on all access doors. The dryer includes over-temperature protection and filter blockage alarms to prevent product damage. Product contact surfaces are polished to Ra 0.8μm finish, meeting sanitary requirements for pharmaceutical and food production. The system supports integration with facility SCADA systems via Ethernet connection, with optional address mapping for enterprise monitoring systems.
This integrated line is suitable for high-volume production of pharmaceutical softgels including prescription medications, OTC drugs, and clinical trial materials. The continuous drying system reduces total production time from encapsulation to final packaging, supporting shorter production cycles for time-sensitive products. The batch logging functions support regulatory requirements for product traceability.
For nutraceutical manufacturers producing fish oil, vitamin, and herbal extract softgels, the dehumidification drying system reduces drying time by 30-40% compared to conventional tray drying. The inline system reduces labor requirements for capsule transfer, lowering operational costs for large batch production.
The servo-driven system maintains consistent fill weight and seal integrity required for paintball production. The controlled drying environment prevents shell cracking and maintains dimensional consistency of paintball capsules during the drying process.
Installation and commissioning are performed by Sinagel technical engineers, typically requiring 7-10 working days on site. Training includes line operation, parameter adjustment, routine maintenance, troubleshooting, and safety procedures for production and maintenance staff. Layout drawings are provided prior to shipment to facilitate facility preparation including utility connections.
The standard warranty period is 12 months from commissioning, covering defects in materials and workmanship. A recommended spare parts list is provided with quotation, including wear parts for 12 months of operation. Remote technical support is available 24 hours via video call, with on-site service available for scheduled maintenance or technical issues that cannot be resolved remotely.
The discharge end of the dryer can be connected to capsule sorting machines, inspection equipment, and packaging lines via standard conveyor connections. The control system provides speed signal output to synchronize downstream equipment speed with production line output. Custom connection interfaces can be provided for specific equipment models.
The complete line requires approximately 12 meters in length × 2.5 meters in width, including clearance for maintenance and operation. Additional space is recommended at the encapsulation end for material preparation and at the discharge end for capsule collection. Exact layout drawings are provided during project engineering.
For standard 10 minim gelatin softgels, the inline drying system typically achieves target moisture content within 24-36 hours, compared to 48-72 hours for conventional tray drying methods. Actual drying time varies based on capsule size, gelatin formulation, fill material, and target final moisture content.
The encapsulation machine can be configured for vegetable gelatin and starch-based capsule formulations with modified spreader boxes and temperature control parameters. The drying system temperature and humidity profiles can be adjusted to accommodate the different drying characteristics of non-gelatin capsule materials.
