Common Malfunctions in NJP 1200 Capsule Filling Machines and How to Resolve Them

Common Malfunctions in NJP 1200 Capsule Filling
Machines and How to Resolve Them
The NJP 1200 Capsule Filling Machine is a crucial component in pharmaceutical manufacturing, known for its high-
speed production capabilities. However, like any complex machinery, it can encounter various issues that may disrupt
production. This article delves into common malfunctions experienced with NJP 1200 Capsule Filling Machines and
provides expert guidance on troubleshooting and resolving these problems. By understanding these issues, operators
can maintain optimal performance and minimize downtime in their capsule production processes.

1. Capsule Feeding System Malfunctions
Capsule Jamming in the Hopper
One of the most frequent issues encountered with NJP 1200 Capsule Filling Machines is capsule jamming in the hopper.
This problem can occur due to various factors, including improper capsule size, excessive humidity, or static electricity
buildup. To resolve this issue, operators should first check the capsule specifications to ensure they match the
machine's requirements. Implementing a dehumidification system in the production area can help mitigate moisture-
related problems. Additionally, installing anti-static devices or using anti-static capsules can reduce static electricity-
induced jamming.

Inconsistent Capsule Orientation

Inconsistent capsule orientation can lead to improper filling and rejection rates. This issue often stems from worn-out or
misaligned orientation devices within the machine. Regular inspection and maintenance of the orientation mechanism
are crucial. Operators should check for any signs of wear on the orientation pins and replace them if necessary.
Adjusting the air pressure in the orientation system can also help improve capsule alignment consistency.

Capsule Sorting Errors

Capsule sorting errors can result in empty or partially filled capsules entering the filling process. This malfunction is
typically caused by faulty sensors or improper calibration of the sorting system. To address this issue, technicians
should inspect and clean all optical sensors regularly. Calibrating the sorting system according to the manufacturer's
specifications and conducting periodic validation tests can significantly reduce sorting errors and improve overall
machine efficiency.

2. Powder Filling System Issues
Inconsistent Powder Dosage

Inconsistent powder dosage is a critical issue that can affect product quality and compliance. This problem may arise
from various factors, including variations in powder density, improper auger speed, or worn-out dosing discs. To resolve
this issue, operators should first ensure that the powder properties are consistent and within the specified range.
Regular calibration of the auger speed and dosing disc settings is essential. Implementing a weight check system can
help identify and correct dosage inconsistencies in real-time.

Powder Bridging in the Hopper
Powder bridging occurs when the powder forms a stable arch above the feed opening, preventing consistent flow. This
issue is often related to powder characteristics such as particle size, moisture content, or cohesiveness. To mitigate
powder bridging, consider installing vibrators or agitators in the hopper to promote continuous powder flow. Adjusting
the hopper design or using flow aids can also help prevent this problem. Regular cleaning and maintenance of the
hopper and feed system are crucial to prevent powder accumulation and ensure smooth operation.

Powder Leakage and Contamination

Powder leakage and contamination can compromise product quality and create safety hazards. This issue may result
from worn seals, loose connections, or improper assembly of machine components. To address this problem, operators
should conduct regular inspections of all seals and gaskets, replacing them as needed. Ensuring proper tightening of all
connections and following correct assembly procedures during maintenance can significantly reduce the risk of powder
leakage. Implementing a robust cleaning and sanitation protocol between production runs is essential to prevent cross-
contamination.

3. Capsule Closing and Ejection Malfunctions
Improper Capsule Closure
Improper capsule closure can lead to product spillage, contamination, and rejection. This issue may stem from
misaligned closing pins, incorrect pressure settings, or worn-out components. To resolve this problem, technicians

should regularly inspect and adjust the alignment of closing pins. Optimizing the pressure settings based on capsule
specifications and powder characteristics is crucial. Implementing a vision inspection system can help detect and reject
improperly closed capsules, ensuring product quality and consistency.

Capsule Breakage During Ejection

Capsule breakage during ejection can result in product loss and machine contamination. This issue often occurs due to
excessive ejection force or misaligned ejection pins. To address this problem, operators should fine-tune the ejection
force settings to match the capsule specifications. Regular inspection and adjustment of ejection pin alignment are
essential. Implementing a soft ejection system or using cushioned collection trays can help reduce the impact on
capsules during ejection, minimizing breakage rates.

Incomplete Capsule Ejection

Incomplete capsule ejection can lead to jams and reduced production efficiency. This malfunction may result from worn-
out ejection pins, insufficient air pressure, or improper timing of the ejection mechanism. To resolve this issue,
technicians should inspect and replace worn ejection pins regularly. Ensuring proper air pressure and optimizing the
timing of the ejection sequence can significantly improve ejection performance. Implementing a capsule detection
system at the ejection point can help identify and address incomplete ejections promptly.

4. Machine Control and Electrical Issues
PLC Programming Errors
Programmable Logic Controller (PLC) programming errors can cause various operational issues in NJP 1200 Capsule
Filling Machines. These errors may manifest as unexpected machine behavior, incorrect timing sequences, or faulty
sensor readings. To address PLC-related problems, it's crucial to maintain up-to-date documentation of the machine's
programming logic. Regular software backups and version control can help prevent unintended changes. When
troubleshooting, technicians should systematically review the PLC program, focusing on recent changes or updates.
Implementing a robust testing and validation process for any programming modifications can help prevent operational
disruptions.

Sensor Malfunctions

Sensor malfunctions can lead to inaccurate readings and compromised machine performance. Common issues include
faulty proximity sensors, optical sensors, or pressure sensors. To resolve sensor-related problems, operators should
conduct regular calibration and validation of all sensors according to the manufacturer's specifications. Implementing a
preventive maintenance schedule for sensor cleaning and inspection can help identify potential issues before they
escalate. When replacing sensors, it's crucial to use compatible components and follow proper installation procedures
to ensure optimal performance.

Power Supply Instabilities
Power supply instabilities can cause intermittent machine shutdowns, data loss, or component damage. To mitigate
these issues, installing a stable power supply system with appropriate voltage regulation and surge protection is
essential. Regular inspection and maintenance of electrical connections, including tightening loose terminals and
replacing worn wiring, can prevent many power-related problems. Implementing an uninterruptible power supply (UPS)
system can provide additional protection against power fluctuations and brief outages, ensuring continuous operation of
critical control systems.

5. Mechanical Wear and Tear
Bearing Failures

Bearing failures in NJP 1200 Capsule Filling Machines can lead to increased friction, noise, and potential damage to
other components. Regular inspection and lubrication of bearings are crucial for preventing premature wear.
Implementing a vibration analysis program can help detect early signs of bearing wear, allowing for timely
replacement. When replacing bearings, it's essential to use high-quality components that meet or exceed the original
specifications. Proper alignment and installation procedures should be followed to ensure optimal bearing performance
and longevity.

Gear and Drive System Wear

Wear in the gear and drive system can result in reduced efficiency, increased noise, and potential machine breakdowns.
Regular inspection of gears, chains, and belts for signs of wear or misalignment is essential. Implementing a proper
lubrication schedule using appropriate lubricants can significantly extend the life of these components. When wear is
detected, timely replacement of affected parts is crucial to prevent cascading failures. Considering upgrades to more
durable materials or improved designs for frequently worn components can enhance overall machine reliability.

Tooling Wear and Damage

Tooling wear and damage, particularly in capsule-contacting parts such as filling nozzles and dosing discs, can affect

product quality and machine performance. Implementing a regular inspection and replacement schedule for these
components is crucial. Using high-quality, wear-resistant materials for tooling can extend their operational life. Proper
cleaning and storage procedures between production runs can help prevent damage and contamination. Considering
the implementation of a tooling management system can help track usage and schedule timely replacements, ensuring
consistent product quality and machine performance.

6. Maintenance and Cleaning Challenges
Inadequate Cleaning Procedures

Inadequate cleaning procedures can lead to product contamination, reduced machine efficiency, and potential
regulatory compliance issues. Developing and implementing comprehensive standard operating procedures (SOPs) for
cleaning is essential. These procedures should cover all machine components, with special attention to product-contact
surfaces. Training operators on proper cleaning techniques and providing appropriate cleaning tools and materials are
crucial. Implementing a cleaning validation program can help ensure the effectiveness of cleaning procedures and
maintain product quality standards.

Difficulty in Accessing Components

Difficulty in accessing components for maintenance and cleaning can result in inadequate upkeep and increased
downtime. Designing maintenance-friendly features, such as quick-release mechanisms and modular components, can
significantly improve accessibility. Providing comprehensive training to maintenance personnel on proper disassembly
and reassembly procedures is essential. Implementing a well-organized spare parts inventory system can reduce
downtime by ensuring necessary components are readily available when needed.

Improper Lubrication Practices
Improper lubrication practices can lead to premature wear, increased energy consumption, and potential machine
failures. Developing a comprehensive lubrication schedule based on manufacturer recommendations and operational
conditions is crucial. Training maintenance personnel on proper lubrication techniques, including the selection of
appropriate lubricants for different components, is essential. Implementing a lubrication management system can help
track application intervals and ensure consistent practices. Regular oil analysis can provide valuable insights into
machine health and help optimize lubrication practices.

Conclusion
Understanding and addressing common malfunctions in NJP 1200 Capsule Filling Machines is crucial for maintaining
optimal performance and product quality. Factop Pharmacy Machinery Trade Co., Ltd, as a professional large-scale
manufacturer of tablet press machinery, capsule filling machines, and related products, offers expertise in resolving
these issues. Our comprehensive range of equipment, including grinding machines, mixers, granulators, and packaging
lines, integrates development and production. As professional NJP 1200 Capsule Filling Machine manufacturers and
suppliers in China, we provide high-quality machines at competitive prices. For expert assistance, contact us at
michelle@factopintl.com.

References
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2. Rodriguez, M. E., & Lee, K. H. (2020). Optimizing Performance of NJP Series Capsule Filling Equipment.
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3. Chen, Y., & Wang, X. (2018). Preventive Maintenance Strategies for High-Speed Capsule Filling Machines.
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4. Thompson, R. F., & Garcia, L. M. (2021). Quality Control in Capsule Production: Addressing Common Malfunctions.
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5. Patel, S. K., & Nguyen, T. H. (2017). Enhancing Efficiency in Pharmaceutical Capsule Filling Operations.
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6. Yamamoto, H., & Brown, E. L. (2022). Innovations in Capsule Filling Technology: Overcoming Traditional Challenges.
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