Optimizing Encapsulation Efficiency With A Focus On Maintenance

Introduction

Production is paramount in the fast-paced world of capsule manufacturing, which can make it difficult to schedule routine and preventative maintenance. However, neglecting the maintenance of machines to maximize production can be a recipe for disaster. Murphy’s Law states that “Anything that can go wrong, will go wrong.” And there’s a lot that can go wrong on high-speed encapsulation machines. Tooling alignments, timing of cams, and the lubrication of bearings, chains, and sprockets are just a few of the tasks required to keep capsule-filling machines running in peak condition. Prioritizing maintenance is crucial to maximizing capsule production. In this article, we focus on the pivotal role maintenance plays in optimizing encapsulation production and efficiency. Highlighting some of the maintenance protocols, proactive strategies, training, tools, and industry best practices that we have experienced to provide capsule manufacturers with some insights on how to uphold peak performance and reliability in their encapsulation processes.

The Lifespan of Encapsulation Machines

Encapsulation machines have a set lifespan that is dependent on their construction and use. Major mechanical overhauls are recommended every four to five years for high-speed tamping-style encapsulation machines. A major overhaul typically includes replacing all of the bearings, seals, springs, shafts, and guide plates as well as a thorough inspection of the cams and other potentially worn parts. Control systems typically last ten-plus years and may require a complete control system replacement of the PLC or if the program has become obsolete. These estimates will vary depending on several variables including the types of products being produced, operator experience, batch sizes, etc; but the key to extending the life of an encapsulation machine is regular and scheduled maintenance. Lack of lubrication, poor timing, and misalignments will cause premature wear and tear. Not replacing worn springs, seals, and bearings can prevent the machine from running faster and lead to major machine crashes, breakdowns, unplanned downtime, and costly repairs.

Striving to Maintain Like-New Condition

Striving to keep the manufacturing equipment in like-new condition can help ensure a high production rate, and accurate dosages, and prevent product issues. Scheduled preventative maintenance is the key to achieving this. Here are some insights:

1. Cleaning: Regular and thorough cleaning and sanitization of the encapsulation machine’s spare parts, tooling, transmission, filters, and electrical cabinet are critical to preventing excessive wear, misalignments, and quality issues.
2. Lubrication: Proper lubrication of the cams, bearings, and chains is essential to ensure smooth operation.
3. Scheduled Inspections and Replacements: Wear and tear is inevitable, especially with seals, springs, and bearings; however, routine maintenance can help identify and replace worn parts before they cause significant wear to synergistic parts like shafts, cams, drives, and motors.
4. Changeovers and Machine Setup: Product changeovers focusing on speed over quality can increase the risk of skipping over or rushing through important maintenance steps, like thoroughly cleaning, lubricating, inspecting, aligning, and timing. Focusing on quality over speed during product changeovers can go a long way in preventing machine crashes and unplanned downtime. It is strongly encouraged to turn the machine by hand during machine setups and changeovers to prevent a crash or damage if a mistake is made or stations are not timed or aligned properly.

Spreadsheets, Calendars, and Software for Scheduled Maintenance

Spreadsheets, calendars, and software programs can be a cost-effective way to track maintenance performed, cost-savings, and the production results of a well-planned and executed maintenance schedule.

On-Hand Spare Parts Inventory

Software programs and spreadsheets can also go a long way in maintaining an on-hand inventory of common wear parts, as well as a locked cage or spare parts cabinet. Managing spare parts inventory and maintenance supplies can have a significant effect on the maintenance team’s performance in preventing and limiting unplanned downtime.

Tools

An old proverb says, “A good workman never blames his tools.” Investing in premium tools can pay off dividends over time in performance and duration. We recommend Milwaukee wrenches, sockets, and Allen wrenches for changeovers. Specialized tools like feeler gauges and a straight edge are required to ensure proper Tamping Ring setup and clearance. Custom tools like Segment Alignment Pins, Dosing Disc Alignment Pins, and Orientation Block Alignment Pins are needed to ensure proper tooling alignments during setups. Having the right tools will increase efficiency and productivity while minimizing machine and safety risks.

Training

Training can be managed in many different ways, and any kind of training is beneficial for the grand manufacturing scheme, mainly when referring to encapsulation machines. Some ways of training include:

• Virtual Training

Virtual training utilizes digital platforms to deliver interactive learning experiences. It can include video tutorials, webinars, online courses, and virtual simulations. Through virtual training, maintenance teams can access information remotely. This method is beneficial for covering theoretical knowledge, troubleshooting scenarios, and software training related to encapsulation machines.

• Classroom Training

Classroom training involves face-to-face instruction in a traditional educational setting. In this setting, trainers can engage directly with maintenance personnel, fostering discussion, answering questions, and providing demonstrations. Classroom training allows for a structured learning environment where concepts can be explained comprehensively and hands-on activities can be introduced in a controlled setting.

• Workshop Training

Workshops are hands-on sessions where maintenance personnel actively engage with the encapsulation machines under the guidance of an experienced trainer. These sessions focus on developing practical skills like machine setup, calibration, preventive maintenance tasks, and troubleshooting techniques. Workshops allow maintenance teams to gain confidence in their abilities and familiarize themselves with the equipment in a real-world context.

• Hands-On Training

Hands-on training involves direct interaction with encapsulation machines, allowing maintenance personnel to practice tasks in a simulated or actual production environment. This training reinforces learning by enabling individuals to apply theoretical knowledge in practical scenarios. Hands-on training is essential for building muscle memory, fine-tuning skills, and addressing specific challenges that may arise during machine operation and maintenance.

By combining these training methods, maintenance teams can comprehensively understand encapsulation machine operation, best practices, and troubleshooting strategies. A multifaceted approach enhances technical proficiency and promotes teamwork, communication, and a proactive approach to equipment management, ultimately contributing to optimized performance, increased production efficiency, and reduced downtime.

Experience

Even the most effective training cannot cover every possible scenario, especially troubleshooting encapsulation machines. This is where experience can be very beneficial. Learning through experience and reaching out to more experienced colleagues and industry experts can significantly help resolve issues quickly and improve maintenance skills.

Conclusion

Unfortunately, machine maintenance can often be overlooked due to a focus on production. Maintenance is the key to optimizing an encapsulation machine’s life, production, and efficiency. Regular maintenance preserves the equipment’s like-new condition, maintains accuracy, and ensures high-quality products for customers. A wise man once said, “If you don’t schedule time for maintenance, your equipment will schedule it for you.”

Author Details

Andres Sandes, Service Manager- KLS Machines Inc.; Brendan Kelly, President- KLS Machines Inc.

As the Service Manager at KLS Machines Inc., Andres Sandes brings 15 years of experience in the capsule filling and solid dose industry to his role. With a background in process management within the nutraceutical industry, Andres possesses valuable insights into production optimization. Committed to continuous improvement, he remains abreast of industry advancements, delivering cutting-edge solutions and unmatched service to clients.

With 20 years of experience in the production and support of high-speed, tamping style, capsule filling machines, Brendan Kelly is a seasoned professional dedicated to improving the capsule production capabilities and efficiency of KLS’s customers.

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