Capsules by Pabitra Subedi
Capsules by Pabitra Subedi
Capsules by Pabitra Subedi
Capsules are solid dosage forms in which drug substance is enclosed within hard or soft
soluble shell. The shells are generally formed from gelatin.
Two types of capsules
1. Hard gelatin capsules
2. Soft gelatin capsules
Advantages
Capsules are tasteless, odorless and can easily be administered.
Combination of powders we can use
There are attractive in appearance.
The drugs having un-pleasant odor and taste are enclosed in a tasteless shell.
They can be filled quickly and conveniently.
Physician can change the dose and combination of drug according to
patient requirement.
They are economical.
They are easy to handle and carry.
Disadvantages
Hygroscopic drugs are not suitable for filling into capsules, because they absorb
water present in capsule shell makes shell very brittle and ultimately lead to crumble
into pieces.
The concentrated solutions which require previous dilution are unsuitable for
capsules because if administered as such lead to irritation into stomach
Capsule size
For human use, empty capsules ranging in size from 000 the largest to 5 the smallest.
Generally, hard gelatin capsule are used to encapsulate between 65 mg to 1 gram
Hard gelatin capsules
B. Opacifing agents used in HGC: Titanium dioxide. Opaque capsules are occupied for
either protection from light or to cover the contents.
E. Moisture content: Finished Hard gelatin capsule normally contains stable moisture
content, from 12 to 15%. It is determined by the toluene distillation method. This moisture
content is critical for the physical properties of the shell as lower content. This causes
gelatin film to
brittle or has a moisture content of less than 18 % causing softness in capsules. Capsules are
kept on RH 40-60% and temperature 21°C – 24°C to avoid extreme temperature during
handling and sorting of capsules.
Preparation of Gelatin
Dipping :
Pairs of the stainless steel pins are dipped into the dipping solution to simultaneously form
the caps and bodies.
The dipping solution is maintained at a temperature of about 500C in a heated, jacketed
dipping pan.
Spinning :
The pins are rotated to distribute the gelatin over the pins uniformly and to avoid the formation
of a bead at the capsule ends.
Drying :
The gelatin is dried by a blast of cool air to form a hard shells.
The pins are moved through a series of air drying kilns to remove water
Stripping :
A series of bronze jaws strip the cap and body portions of the capsules from the pins.
Trimming and joining
The stripped cap and body portions are trimmed to the required length by stationary knives.
After trimming to the right length, the cap and body portion are joined and ejected from the
machine.
Polishing
Pan Polishing: Acela-cota pan is used to dust and polish.
Cloth Dusting: Capsule are rubbed with cloth.
Brushing: Capsule are feed under soft rotating brush
Types of excipients used in powder-filled capsules:
Diluent — Diluents are the excipients that are usually present in the greatest concentration in
a formulation, and they make up the necessary bulk when the quantity of the active ingredient
is deficient in making up the required bulk, e.g., Lactose, maize starch, calcium sulfate, etc.
Lubricants and Glidants — This reduces powder to metal adherence and promotes free
flow properties, e.g., Magnesium stearate talc.
Wetting agents — A wetting agent helps in the penetration of Water for less soluble drugs,
e.g., Sodium lauryl sulfate.
Disintegrates– Disintegrates help in splitting the powder mass. e.g., cross povidone and
sodium starch glycolate.
Rectification: During Rectification empty capsules are oriented so that they can be laying in
the same direction, i.e., laying the capsule Body end in downward direction. Moving
forwards caps will separate from the Body as the upper plate slides towards the left, leaving
the lower plate exposed to the filling, it leads to feeding coming from the hopper filling the
capsule body.
the last step is the replacement of caps on the Body and the ejection of filled capsules from
the die, parallelly de-dusting, polishing, and printing are done.
2. Rotofil
3. Hofliger
4. Macofar
5. MG2
6. Osaka
7. Zanasi
8. Perry/ Accofil In the case of farmatic, Rotofil, Macofar, MG2, and Zanasi equipment, the
power must be sufficient cohesiveness to retain slug or pellet during the delivery to the
capsules.
1. Rotosort: A mechanically shorting device that removes loose powder, and unfilled joined
capsules. Filled or unfilled Bodies and loose caps.
2. Erweka KEA: For both de-dusting and polishing 3. Seidender machine: for visual
inspection by using a belt.
The Gelatin shell dissolves rapidly and ruptures, which results in the rapid release of a drug,
although in capsule no compression force is required to manufacture as in tablets. So it gives
more bioavailability rather than tablets.
(b) Acid solubility: Dissolve in less than 5 minutes in 0.5% aqueous HCI at 36-38° C.
Disadvantages of Hard gelatin capsules including; Highly soluble salts like iodides,
bromides, and chlorides generally should not be dispensed in HGC. It may cause gastric
irritation due to Its rapid release and formation of high drug concentrations in localized areas.
FILLING OF HARD GELATIN CAPSULES
Hand Operated Capsule Filling Machine is table top machine suitable for pilot &
production batch requirements. Machine is having 300 holes with 25 x 12 combinations made
in Stainless Steel constructions meeting GMP requirements. Machine can fill size 00 to size 5
capsules with
help of different machines and interchangeable parts. Assembly has been done in such a way
that it can be easily dismantle for cleaning operations
Synonyms: Hand Operated Capsule Filler, Manually Operated Capsule Filling Machine
Application: Filling Capsules with powder, pellets, granules & tablets
Usage: Pharmaceutical, Nutritional, Biotech, Health Supplement, Food Product & Cosmetics
Suitability: Hard Gelatin, HPMC & Veg Capsules in 00, 0, 1, 2, 3, 4 & 5 sizes
Process Operation
Place empty capsules onto the loading tray and place tray onto the machine.
Check the front knob it should be turned to the right.
Pull locking lever forward. Push down long handle which will lifts the caps off all
the bodies. Set aside the tray containing all the caps.
Push locking lever back, by which capsule bodies will drop down and become
level with filling surface.
Place powder tray on filler: keeps powder from spilling.
Pour & spread the pre-measured powder. Move extra powder onto powder
tray's shelf. Lower tamper and lock.
Turn handle to compress powder: this allows you to fill more powder in each capsule.
Raise tamper & spread extra powder from shelf into capsules: ensures uniform
fill weights.
Return the tray containing caps to filler. Turn front knob to the left and lower locking
plate. Engage lock for locking plate.
Hold tamper handle and push down on long handle. Bodies are pushed up into
caps: all the capsules are now locked in one step.
Disengage lock for locking plate. Lift locking plate and turn front knob to the right.
Push down long handle and remove tray of completed capsules.
Capsules are filled now. Turn tray and all the capsules will get out from the tray.
Usage: Pharmaceutical, Nutritional, Biotech, Health Supplement, Food Product & Cosmetics
Suitability: Hard Gelatin, HPMC & Veg Capsules in 00, 0, 1, 2, 3, 4 & 5 sizes
Working principle
Empty capsules of suitable size are loaded in capsule hopper of filling machine. Powder then
loaded into a separate hopper. This is a corkscrew driven hopper, which allows a constant fill
throughout each capsule. The operator then uses the vacuum sucker to individually sort out
and fill the capsules into the loading rings. Loading Rings can be made from 00 to 5 sizes as
per requirements. The operator then uses the vacuum to separate the capsules.Once the
capsules are separated, the loading rings are pulled apart to release just the bottom section.
This bottom section is then placed into the filling part of the machine. Once the loading rings
has been placed into this section of the machine, the operator can switch on the filling. This
causes the filler to slide across onto the capsules, and the capsules to rotate beneath it. The
corkscrew then evenly forces the powder down into the capsules. This ensures that each
capsule is of the same
size and weight. The two loading rings are then placed back together and placed into the
sealing section of the capsule filling machine. Once they are aligned, the operator closes the
guard and uses air pressure to seal the capsules. The capsules are then released from the
loading ring.Once the capsules have been produced, there is also a capsule polishing option
for this machine. The capsule polishing has a set of corkscrew brush bristles inside and uses a
dust extractor unit connect with this capsule polishing machine. This dust extractor system
de-dust the capsules by the vacuum, to leave them with a high-quality and professional finish.
After starting up the machine, the empty capsules in hopper will be fed into the slot of
magazine vertically. With each stroke of machine, the fingers of magazine will release one
row of capsules into rectifier raceway. The horizontal fingers rectify the direction of capsules
and vertical fingers push the capsules into hole of segment with all caps on the up position.
The capsules in the holes are sent to each working station along with the intermittent rotation
of the turn table.
At the 1st & 2nd station, the vacuum system separates the capsules in position.
At 3rd station, the lower segment with capsule body extends out ready for the
At the 5th station, the tamping pins push the pressed powder slug into capsule
At the 10th station the holes of segments are cleaned by vacuum cleaner and compressed air.
Then the segments are ready for next cycle of operation.
The powder from a SS hopper entered to a chamber of dosing plate & temping pins for
dosing, the height of the powder is controlled at chamber by a material level sensor. Tamping
device is work by a 6 working station of intermittent mechanism, there are 6 groups of
standard holes on dosing disc. The powder filled in holes was made of a slug that reaches the
weight of dose after 5 tamped. At the 6th working station the slug pushed by tamping pin into
capsule body. Adjusting the height of tamping pin holder can be changed the filling weight of
powder.
Soft Gelatin capsules are one piece, hermetically sealed, soft gelatin shells containing a
liquid, a suspension, or a semisolid.
The shape of soft gelatin capsule are round, oval, oblong, tube
The basic component of soft gelatin shell is gelatin; however, the shell has been plasticize
The ratio of dry plasticizer to dry gelatin determines the “hardness” of the shell and can vary
from 0.3-1.0 for very hard shell to 1.0-1.8 for very soft shell
The residual shell moisture content of finished capsules will be in the range of 6-10%
Formulation
Formulation for soft gelatin capsules involves liquid, rather than powder technology.
Materials are generally formulated to produce the smallest possible capsule consistent with
maximum stability, therapeutic effectiveness and manufacture efficiency.
The liquids are limited to those that do not have an adverse effect on gelatin walls.
Emulsion cannot be filled because water will be released that will affect the shell
Plate process
Rotary die process
Reciprocating die
Accogel machine
Plate process
Place the gelatin sheet over a die plate containing numerous die pockets.
Application of vacuum to draw the sheet in to the die pockets.
Fill the pockets with liquid or paste.
Place another gelatin sheet over the filled pockets, and
Sandwich under a die press where the capsules are formed and cut out
In this machine the soft gelatin capsules are prepared & then filled immediately with liquid
medicaments it is having two hoppers & two rotating dies
Liquid mixture is placed in one hopper & the liquid medicament in other Hooper.
The two rotating dies rotate in opposite directions when the fluid gelatin mixture enters the
machine from the hopper it produces two continuous ribbons .
At this stage the measured quantity of the medicament is filled in to it with the stroke of a
pump with the subsequent movement of the dies the other half capsule is formed.
As the die rolls rotate, the convergence of the matching die pockets seals and cuts out the filled
capsules
Accogel Capsule Machine
Accogel Capsule Machine Or Stern machine, uses a system of rotary dies but is unique in that
it is the only machine that can successfully fill dry powder into a soft gelatin capsule.
Water immiscible, volatile or more likely more volatile liquids such as vegetable oils, mineral
oils, medium-chain triglycerides and acetylated glycerine.
Water miscible, non-volatile liquids such as low molecular weight PEG have come in to use
more recently because of their ability to mix with water readily and accelerate dissolution of
dissolved or suspended drugs.
All liquids used for filling must flow by gravity at a temperature of 350C or
It is defined as the load in grams required to push a standard plunger 4 mm into the gel.
The gelatin used in hard capsule manufacture is of a higher bloom strength (200-250 g) than
that used for soft capsules (150 g) because a more rigid film is required for the manufacturing
process
▸ Base adsorption is expressed as the number of grams of liquid base required to produce a
capsulatable mixture when mixed with one gram of solids.
▸ The base adsorption of a solid is influenced by such factors
The solids particle size and shape,
Its physical state
Its density
Its moisture content, and
Its lipophilic or hydrophilic nature
The base adsorption is obtained by
weight of the base/weight of the solid =Base Adsorption
Determination of Base Adsorption
Weight the definite amount (40g is convenient) of the solid substance into a 150ml tared
beaker
In a separate 150ml tared beaker place 100g of the solid base
Add small amount of liquid base into the solid and stir it with spatula until consistent soft
ointment is produced
Continue to add liquid until the mixture flows steadily from the spatula blade when held at a
45 degree angle above the mixture
Calculate the base adsorption using the above given formula
Minim per gram" FACTOR (M/g) OF THE SOLID
▸ The base adsoorption is used to determine the "minim per gram" factor (M/g) of the solid(s).
▸ The minim per gram factor is the volume in minims that is occupied by one gram of the
solid plus the weight of the liquid base(BA) required to make capsulatable mixture.
▸ The minim per gram factor is calculated by dividing the weight of the base plus the gram of
solid base (BA+S) by the weight of the mixture (W) per cubic centimeter or 16.23 minims (V).
(BA+S) x V/W = M/g
Thus lower the base absorption of the solids and higher the density of the mixture, the smaller
the capsule will be.
Quality Control Tests for Capsule Drug Products
In-process quality control tests for capsule drug products
In-process quality control tests for capsule drug products are carried out at predefined
intervals during the product manufacturing, by the manufacturing personnel, and their results
recorded on the batch record. Adverse findings in these tests can be used as a guide to
altering the manufacturing-process parameters.
During the encapsulation of soft gelatin capsules, the following parameters are usually
closely monitored and controlled:
Visual inspection, fill weight, and fill-weight uniformity are the key in-process tests used for
hard gelatin capsules.
Finished capsules are subjected to a number of tests in accordance with compendial standards
and regulatory requirements for unit dose capsule products. These batteries of tests help
identify whether the batch is acceptable for marketing or its intended usage.
Soft gelatin capsules are tested for physical integrity (absence of leakage) by visual
inspection. Similarly, hard gelatin capsules are tested for any breach of physical integrity
(breakage or opened cap and body).
All capsules are tested for drug content (potency, as a per cent of label claim). In addition,
most drug products are tested for related substances or impurities. These must meet
predefined specifications for a batch to be acceptable.
Ten hard gelatin capsules are usually weighed individually and the contents are removed. The
emptied shells are individually weighed and the net weight of the contents is calculated by
subtracting the weight of the shell from the respective gross weight. The content of active
ingredient in each capsule may be determined by calculation based on the per cent drug
content in the formulation.
e. Weight variation test for soft gelatin capsules
For soft gelatin capsules, the gross weight of 10 gelatin capsules is determined individually.
Then each capsule is cut open with a suitable clean, dry cutting instrument (e.g., scissors or a
sharp open blade), and the contents are removed by washing with a suitable solvent (that
dissolves the fill but not the shell). The solvent is allowed to evaporate at room temperature
over a period of about 30 minutes, followed by weighing of the individual washed shells. The
net contents are calculated by subtraction and the content of active ingredient in each of the
capsules can be determined by calculation based on the per cent drug content in the
formulation.
Fill-weight variation of capsules is often a function of equipment setup and filling operation.
An automated capsule sizing machine and/or weight checker is frequently used to discard
over- or under filled capsules.
f. Uniformity of content
This test is performed only when the content is specified in the individual monographs and
when capsules fail weight variation test. If the weight of capsules is completely filled no need
of test. Unless otherwise stated in the monograph for an individual capsule, the amount of
drug substance, determined by assay, is within the range of 85.0 % to 115.0 % of the label
claim for nine (9) of ten (10) dosage units assayed, with no unit outside the range of 75.0 %
to 125.0 % of the labelled drug content. Additional tests are prescribed when two or three
dosage units are outside of the desired range but within the stated extremes.
Disintegration of hard and soft gelatin capsules is evaluated to ensure that the drug substance
is fully available for dissolution and absorption from the gastrointestinal tract. The
compendial disintegration test for hard and soft gelatin capsules follows the same procedure
and uses the same apparatus described in the article “Quality Control Tests for Tablets”.
The capsules are placed in the basket-rack assembly, which is repeatedly lowered 30 times
per minute into a thermostatically controlled bath of fluid at 37 ± 2 ˚C and observed over the
time described in the individual monograph.
To fully satisfy the test, the capsules disintegrate completely into a soft mass with no firm
core and only some fragments of the capsule shell.
h. Dissolution test for capsules
Drug absorption and physiological availability depend on the drug substance being in the
dissolved state at the site of drug absorption. The rate and extent of dissolution of the drug
from the capsule dosage form is tested by a dissolution test. This test provides means of
quality control in ensuring that different batches of the drug product have similar drug release
characteristics and that a given batch has similar dissolution as the batch of capsules that was
shown initially to be clinically effective
The compendial dissolution test for capsules uses the same apparatus, dissolution medium,
and test as that for uncoated and plain coated tablets. However, in instances in which the
capsule shells interfere with the analysis, the contents of a specified number of capsules can
be removed and the empty capsule shells dissolved in the dissolution medium before
proceeding with the sampling and chemical analysis.
If the capsule floats on the surface of the dissolution fluid, a small, loose piece of nonreactive
material, such as a few turns of a wire helix, may be attached to the dosage form to force it to
sink to the bottom of the vessel.
i. Moisture content
Water content of the entire capsule or the capsule contents are determined by Karl Fisher
titrimetric to enable the correlation of water content with the degradation profile or drug-
release characteristics of capsules.
k. Microbial content
The capsules are tested to ensure lack of growth of bacteria and mould by microbiological
tests. These tests are usually carried out by incubation of the capsule contents in a growth
medium and counting the colonies formed after a predefined period of time. Selection of
the growth
medium and duration of the test, as well as maintenance of aseptic conditions during the
testing, are critical to successful assessment of microbial contamination by this method.
Shelf-life test
These tests are frequently carried out after defined periods of storage at predetermined
conditions. They help to assign and verify the shelf life and usability of the drug product.
Type A Type B
It is derived mainly from pork skins by acid It is obtained from bones (“green” (fresh))and animal skins by
processing. alkaline processing.
Preparation to be encapsulated-
pH – 2.5 to 7.5
More acidic preparation – cause hydrolysis – Result in leakage
More alkaline – tannin – water solubility of the shell is decreased
The moisture content of capsule shell determined by – Toluene distillation method