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    Capsule filling machine

    Syntegon capsule filler

    When precision, flexibility, and safety are essential, our capsule filling machine solutions deliver. Whether you're producing pharmaceuticals or nutritional supplements, Syntegon supports you from R&D to high-output manufacturing, filling powders, mini-tablets, pellets, liquids and combinations into HPMC or gelatin capsules.

    With modular platforms and robust containment concepts (up to OEB 5), each capsule filling machine ensures safe, compliant processing even for highly potent APIs. No matter your batch size or challenge, we help you meet the highest pharmaceutical standards with confidence.

    Talk to our experts or download the brochure below to discover the right solution for your needs.

    Connect with an expert Download Brochure

    Capsule filling applications

    syntegon-capsule-powder
    Powders/pellets

    Dosing station with optimized slide-gate technology for the filling of powders, granules, and pellets.

    syntegon-capsule-pellets
    Pellets

    The pellet station is a gentle, precise, and compact option for the volumetric dosing of pellets with different characteristics.

    syntegon-capsule-tablets
    (Micro-) tablets

    The tablet station doses single and multiple tablets into capsules gently and precisely – from big oblong to micro-tablets.

    syntegon-capsule-micro
    Vacuum-wheel dosing

    Vacuum-wheel dosing is especially suited for dry powder inhalation (DPI) and active pharmaceutical ingredient (API) dosing with a high accuracy for small quantities.

    syntegon-capsules-liquids
    Liquids

    The liquid station enables the precise volumetric dosing of hydrophilic to thixotropic liquids. It can also heat liquids for optimum viscosity during the filling process.

    pharmaceutical-capsule
    Combinations

    The GKF series can fill a wide array of product combinations thanks to its modular assembly. Various successful projects underline our expertise.

    Why choose a Syntegon capsule filler?

    capsule-filling-machine

    Capsule filling machine manufacturer

    With over 50 years of experience, Syntegon is your trusted partner for capsule filling machine solutions in pharma from R&D to high-volume production. We offer filling technologies for powders, pellets, tablets, liquids and combinations, backed by modular, flexible designs and advanced process control.

    Key features include:

    • NWDS sensor and PAT for real-time quality control

    • Integrated IPC and capsule checkweighing

    • Tablet counting systems

    • Containment solutions up to OEB 5 for operator safety

    Our capsule filling machines

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    Our capsule filling machine portfolio at a glance

    automatic-capsule-filler-Syntegon-GKF-2600

    GKF Performance series

    The future-proof GKF Performance series offers flexible capsule filling machine platforms that meet the highest pharmaceutical manufacturing standards. With over 50 years of experience, Syntegon delivers machines that handle complex dosing processes across all production scales.

    They fill powders, pellets, (mini-)tablets, granules, liquids, or combinations into HPMC or gelatin capsules, and include fully integrated inspection technologies for added process reliability.

    All models are also available with ProTect and HiProTect containment systems for maximum operator safety when handling potent APIs up to OEB5. Learn more about how the GKF Performance series supports your capsule filling needs.

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    capsule-filler-GKF-1400

    GKF Selection series

    The GKF Selection series sets the standard for modern, flexible, and reliable capsule filling operations. Designed for versatility, these capsule filling machines can handle a wide range of products from powders and pellets to (mini-)tablets, granules, liquids, or combinations filling them into hard shell capsules (HPMC or gelatin).

    With a modular design that supports fast changeovers and user-friendly operation, the GKF Selection series is well-suited for both pharmaceutical applications and health & nutrition products.
    Learn more about how the GKF Selection series can optimize your capsule production.

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    capsule-filling-machine-Syntegon-GKF-720

    GKF Containment series

    Containment is essential when it comes to protecting operators during OSD (Oral Solid Dosage) processing. At Syntegon, we ensure safe separation between product and personnel areas using advanced barrier systems designed to prevent contamination and ensure compliance.

    We offer two proven containment solutions tailored to your needs: ProTect, for applications up to OEB 4, and HiProTect, for high-potency production up to OEB 5. Additionally, our portfolio includes three adaptable cleaning approaches for closed capsule filler machines, allowing you to configure the ideal setup with support from our experts. Learn more about how our containment solutions can enhance both safety and efficiency in your production.

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    capsule-filling-Syntegon-GKF-capsylon-1505

    GKF Capsylon series

    The GKF Capsylon machine series is built specifically for the needs of the health and nutrition industry. Designed with efficiency in mind, it delivers Syntegon’s trusted quality at an attractive price-performance ratio ideal for supplement producers looking to scale.

    These capsule fillers handle powders, pellets, and granules across various capsule sizes, while supporting fast changeovers, intuitive operation, and easy cleaning. Whether you're boosting output or aiming to reduce unit dosage costs, the GKF Capsylon series is a smart, scalable solution for modern production needs. Learn more about how it can help optimize your capsule filling operations.

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    Service Agreements
    Service Agreements

    Find out more about our Service Agreements here.

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    Digital Solutions
    Digital Solutions

    Find out more about Digital Solutions here.

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    Maintenance
    Maintenance

    Find out more about Maintenance here.

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    Technical Support
    Technical Support

    Find out more about Technical Support here.

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    Modernizations
    Modernizations

    Find out more about Modernizations here.

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    Training
    Training

    Find out more about our Training here.

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    Expert Services
    Expert Services

    Find out more about our Expert Services here.

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    Downloads

    Pharma Solid overview brochure
    Pharma Solid overview brochure

    Discover our solutions for mixing, drying, granulating, coating, capsule filling, and tablet pressing.

    Download
    R&D Equipment Brochure
    R&D Equipment Brochure

    Syntegon’s R&D machine portfolio covers all process steps: mixing, granulating, drying, tablet pressing and coating, pellet manufacturing, capsule filling and banding.

    Download
    Automated Process Development (APD)
    Automated Process Development (APD)

    A sophisticated approach to laboratory automation.

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    capsule-filling-machine-contact

    Interested in a capsule filling machine?

    Contact us

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    FAQs on capsule filling

    Syntegon’s in-house OSD Customer Center provides the entire processing infrastructure, from clean room facilities to equipment for processing trials. The Customer can perform the trial themselves or have the Syntegon process specialists perform the trials for them. Customers can bring their own capsules or use empty capsules provided by Syntegon for the machine trials. 

    The capsule filling process on our GKF capsule fillers involves several steps

    1. Capsule alignment and separation: After loading of the empty capsules into the segment of the GKF capsule filler, the capsules are aligned and separated.
    2. Upper/lower segment separation: The empty capsules will be separated into two parts – the upper part and the lower part (capsule cap and body respectively), which are filled with the product at the dosing station.
    3. Ejection of non-separated capsules: In this station all empty capsules that have not been separated earlier in the process, are removed.
    4. Dosing station for powder or pellets: The lower part of the empty capsule is filled with the Customer’s product (powder, pellets, tablets or liquids).
    5. Segment alignment: This station ensures the correct alignment of the upper and lower capsule parts in order to achieve a secure seal.
    6. Capsule closing station: The upper part of the capsule is sealed together with the lower part which has been filled with the Customer’s product (powder, pellets, tablets or liquids).
    7. Ejection of filled capsules: After the capsule closing station, the GKF capsule filler identifies the successfully sealed capsules and removes them from the machine.
    8. Segment cleaning station: In the last station of the capsule filling process, the capsule segments are cleaned to ensure that empty capsules can be loaded for rhe next filling cycle. 
    According to the Customer’s preferences and the specification of the GKF capsule filler, additional stations can be added. In addition, several quality control and inspection technologies are offered for better process monitoring and assurance.
    All types of empty capsules can be filled on the GKF capsule filler. The two main types are gelatin capsules and hydroxypropylmethylcellulose (HPMC) capsules. The HPMC capsules offer a vegan alternative to the gelatin capsules.

     

    Different types of components and component combinations can be dosed on our GKF capsule filling machines:
     
    Powder: Dosing station with optimized slide-gate technology for the filling of powders, granules, and pellets.
     
    Pellets: The pellet station is a gentle, precise, and compact option for the volumetric dosing of pellets with different characteristics.
     
    (Micro) Tablets: The tablet station doses single and multiple tablets into capsules gently and precisely – from large oblong to micro-tablets.
     
    Micro-Dosing: Vacuum-wheel dosing is especially suited for dry powder inhalation (DPI) and active pharmaceutical ingredient (API) dosing with a high accuracy for small quantities.
     
    Liquids: The liquid station enables the precise volumetric dosing of hydrophilic to thixotropic liquids. It can also heat liquids for optimum viscosity during the filling process.
     
    Combinations: The GKF series can fill a wide array of product combinations thanks to its modular assembly. Various successful projects underline our expertise.
     
    Specials: Capsule into capsule. 

    We offer a range of inspection technologies in our portfolio to meet your needs. Our portfolio of inspections technologies include:
     
    KKE series: The KKE capsule checkweighing series sets the standard in 100 % capsule weighing. With its mechanical pre-dedusting system, the precise gravimetric weighing technology makes the KKE series the ideal choice for your capsule checkweighing needs. The platforms also answer the growing needs of the nutraceutical and health industry (supplements) in terms of process control and increases product quality in your capsule production. Need more information? Learn more about our KKE series here.
     
    In-process control: The integrated gravimetric scale system ensures an automatic statistical capsule check weighing for low fill-weight capsules. It allows the Customer to analyze those capsules in real-time, improving quality and reducing waste.
     
    Net-weight-detection system (NWDS): 100% net weight control system with  weight determination via electromagnetic field sensor. During the dosing process, the dosing mass passes through a mass detection sensor. Here, the interruption generated in the sensor field is measured against a pre-set mass to weight reference that is set during an automated teach in process with the integrated IPC.
     
    Process optimization technologies: 

    • PAT Classic (Process Analytical Technologies): The PAT Classic system offers powder height detection, ejection force detection and closing force detection. It supports operators in running a stable capsule filling process, its also avoids dosing errors and product loss. Furthermore, it can prevent machine damages and increases the overall yield.
    • APD (Automated Process Development): Automated process development (APD) is a sophisticated approach for fast and efficient process development for new formulations and optimization of existing products. Combining systematic planning (DoE = Design of Experiments) with a patented automated execution set-up on a capsule machine, APD is a unique methodology which enables the performance of a higher number of experiments in a shorter time with reduced product consumption.
    • ASB Function: The integrated automated troubleshooting function ensures maximum productivity and quality. It automatically corrects malfunctions in the capsule handling process, resulting in less machine downtime.
    • Single Capsule Rejection: Non-separated capsules are automatically rejected during the capsule filling process.
    • No Cap No Fill: If a defined number of caps are missing the no cap no fill function switches off the subsequent dosing stations. Un-filled capsules are then ejected at the cleaning station. No Cap No Fill improves yield and reduces product loss.