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YWJ250-IIIA(SERVO)+SGJ-I
The YWJ250-IIIA(SERVO)+SGJ-I integrated soft capsule production and drying line combines a servo-driven high-speed encapsulation machine with a double-layer rotary cage dryer, providing a complete solution for softgel manufacturing from raw material input to dried finished capsules. Designed and manufactured by Beijing Sinagel Technology, this production line incorporates servo motion control technology and improved drying system design based on feedback from commercial production facilities. The integrated system reduces material handling steps and provides consistent production conditions for softgel manufacturing operations.
The YWJ250-IIIA servo encapsulation machine uses independent servo motors for die roll drive, injection pump actuation, and gelatin feed, enabling precise synchronization of all forming functions. The SGJ-I double-layer rotary cage dryer provides staged drying with independent speed and direction control for each cage section. The integrated line supports continuous production with automatic capsule transfer from encapsulation machine to dryer inlet, eliminating manual collection and loading of wet capsules.
All components in contact with capsules or gelatin are constructed from 304 stainless steel, meeting GMP material requirements for pharmaceutical and food production. The dryer cabinet features fully welded stainless steel construction with tempered glass observation doors, allowing visual inspection of capsules during drying without opening the cabinet. Rotary cages use perforated stainless steel sheet with 3mm diameter holes, sized to retain capsules while allowing maximum airflow. The entire line includes stainless steel utility piping with sanitary fittings.
The servo drive system reduces mechanical vibration compared to gear-driven machines, operating at noise levels below 72 dB(A) at full production speed. The alignment-free die roll mounting system reduces die changeover time to less than 20 minutes, improving equipment utilization for multi-product facilities. The double-layer dryer provides approximately 40% more drying capacity than single-layer designs with equivalent footprint. Each cage section rotates independently, with programmable forward/reverse timing to prevent capsule clumping during initial drying stages.
The production line requires a 380V three-phase power supply with 63A dedicated circuit protection. Compressed air supply should be filtered and dried, maintained at 0.6-0.8 MPa with flow rate of 0.4 m³/minute. Chilled water at 10-15°C is required for the encapsulation machine cooling circuit at 15 L/minute. The dryer requires conditioned air supply from facility dehumidification system, with inlet air humidity below 30% RH for optimal drying performance. Installation area should provide level concrete floor with 1.2 meter minimum clearance around all sides.
The line uses an integrated PLC control system with 10-inch color touchscreen at the encapsulation station and a secondary control panel at the dryer discharge. The HMI displays real-time production data including running speed, output count, temperature readings, and fault alarms. Production recipes for different capsule sizes and formulations can be stored in the system memory, enabling quick parameter recall during product changeover. The system includes password-protected access levels for operators, maintenance staff, and supervisors.
The YWJ250-IIIA uses ceramic injection plungers for wear resistance and consistent dosing accuracy. The dual cooling system combines water cooling for die rolls and air cooling for gelatin ribbons, preventing gelatin softening in high temperature environments. The automatic lubrication system applies measured quantities of food-grade lubricant to die roll surfaces, with oil consumption below 0.5L per 8-hour shift. The spreader box includes automatic gelatin level control, maintaining consistent film thickness without manual adjustment.
The SGJ-I dryer uses a tool-less cage removal design, allowing rotary cages to be rolled out for cleaning without heavy lifting equipment. The air supply system uses HEPA filtration for incoming air, preventing particulate contamination of capsules during drying. Each drying section includes independent temperature control and air volume adjustment, allowing creation of staged drying profiles that reduce capsule shell cracking. The double-layer design reduces facility floor space requirements while maintaining the same total drying volume as single-layer dryers.
This production line supports GMP-compliant manufacturing of pharmaceutical softgels including oil-based drugs, suspension formulations, and combination products. The stainless steel construction and sanitary design support cleaning validation requirements for pharmaceutical production. The servo control system provides consistent fill weight accuracy required for dosage form products.
The machine configuration supports production of vegetable-based softgels using carrageenan, starch, and other non-gelatin film formers. The temperature control system can be adjusted to the higher melting points and different drying characteristics of vegetable capsule materials. The machine also supports production of cosmetic capsules, paintballs, and other specialty soft capsule products.
The quick die change and recipe storage functions make this line suitable for contract manufacturing operations producing multiple capsule sizes and formulations. The modular dryer design allows addition of extra drying sections if production capacity increases in the future.
Sinagel technical engineers provide on-site installation, commissioning, and training for each production line. Installation typically requires 5-7 working days, including utility connection verification, test runs, and production trial runs. Training covers machine operation, cleaning procedures, die changeover, routine maintenance, and basic troubleshooting for production and maintenance personnel. Operation and maintenance manuals are provided in English with detailed diagrams and parts lists.
Standard warranty covers 12 months from the date of commissioning. A recommended spare parts kit is shipped with each line, including seals, filters, and common wear parts for the first year of operation. Additional spare parts can be ordered and shipped via international express. Technical support is available via email, phone, and video call, with response within 24 working days for technical inquiries. On-site service visits can be scheduled for major maintenance or process optimization support.
The SGJ-I dryer uses facility-supplied dehumidified air for drying, while the SGL70 model includes an integrated built-in dehumidification system. This model is suitable for facilities that already have central dehumidification systems, while the SGL70 model is appropriate for facilities without dedicated environmental control in production areas.
The dryer uses a modular design that allows addition of 2-4 extra drying sections if required for products with longer drying cycles or higher production volumes. Additional sections can be added at the time of manufacture or retrofitted to existing lines within 2 years of installation.
Daily maintenance includes cleaning of gelatin contact parts, inspection of lubrication levels, and verification of cooling water flow. Weekly maintenance includes filter inspection and cleaning of exterior surfaces. Preventive maintenance including seal replacement and drive belt inspection is recommended every 2000 operating hours.
The machine can fill oil-based formulations including hemp oil and CBD extracts, provided the materials have appropriate viscosity characteristics for pump filling. The encapsulation parameters may require adjustment based on specific material properties, which can be tested during factory acceptance testing if material samples are provided.
