Proper maintenance is the key to maximizing the lifespan, reliability, and performance of your capsule filling machine. Whether you operate a manual SL-400, a semi-automatic DTJ-C, or a fully automatic NJP-600/800, following a structured maintenance routine will prevent costly breakdowns, ensure consistent filling quality, and protect your investment.

This guide covers daily, weekly, and monthly maintenance procedures that every capsule filling machine operator should follow.

Daily Maintenance Procedures

Daily maintenance should be performed at the beginning and end of each production shift. These procedures take 15-30 minutes but are critical for maintaining machine performance and product quality.

Pre-Start Checklist

• Visual inspection: Check the machine exterior for any loose components, damaged wiring, or signs of wear
• Air pressure check: Verify compressed air pressure is within the specified range (typically 0.4-0.7 MPa for NJP machines)
• Vacuum check: For NJP automatic machines, verify the vacuum system is operating correctly for capsule positioning
• Power supply: Confirm stable power supply and check emergency stop buttons are functional
• Hopper inspection: Ensure powder and capsule hoppers are clean and free of residual material
• Lubrication points: Check that all daily lubrication points have adequate lubricant

End-of-Shift Cleaning

Thorough cleaning at the end of each shift is essential, especially in pharmaceutical and nutraceutical environments where cross-contamination is a serious concern:

1. Power down: Turn off the machine and disconnect power before cleaning
2. Remove residual powder: Empty the powder hopper and use a vacuum to remove all powder residue from the filling mechanism
3. Disassemble contact parts: Remove dosing discs, capsule segments, and filling tubes. Clean each part with purified water and an appropriate cleaning agent
4. Wipe down surfaces: Use a lint-free cloth dampened with 70% isopropyl alcohol to wipe all exterior surfaces
5. Clean the turntable: For NJP machines, carefully clean each station of the turntable, paying attention to capsule holder holes
6. Dry all parts: Air dry or use clean compressed air to dry all components completely before reassembly
7. Reassemble: Reinstall all cleaned parts and verify proper alignment

Daily Lubrication

Proper lubrication prevents premature wear of moving components. Key daily lubrication points include:

• Cam followers and rollers: Apply food-grade grease to cam tracks and follower bearings
• Guide rails: Lightly oil the guide rails for the capsule feeding mechanism
• Bearings: Check sealed bearings for smooth operation; replace if noise or resistance is detected
• Tamping pins: Apply a thin film of food-grade lubricant to tamping pins to prevent powder adhesion

Always use food-grade lubricants (NSF H1 certified) for all points that may have incidental contact with product.

Weekly Maintenance Procedures

Weekly tasks go beyond daily cleaning to address components that don't need daily attention but require regular inspection.

Deep Cleaning

• Perform a more thorough disassembly than daily cleaning, including removing the turntable for NJP machines
• Use compressed air to blow out powder from internal channels and hard-to-reach areas
• Inspect and clean the dust collection system filters
• Check and clean the capsule orientation mechanism and feeding tubes
• Clean the touch screen and control panel with approved electronics cleaner

Mechanical Inspection

• Belt tension: Check drive belts for proper tension and signs of wear. Replace if cracked or frayed
• Chain condition: Inspect chains for proper tension and lubrication
• Fastener check: Verify all bolts and screws are tight, especially on the filling mechanism and turntable
• Pneumatic lines: Inspect air lines for leaks, cracks, or loose fittings
• Seal inspection: Check O-rings and gaskets for wear or damage. Replace as needed

Calibration Verification

• Run a test batch of 100 capsules and verify fill weight uniformity
• Check the rejection system is properly identifying and ejecting unqualified capsules
• Verify capsule closing force is appropriate — no loose caps or crushed capsules
• Document test results for GMP compliance records

Monthly Maintenance Procedures

Monthly maintenance addresses deeper system components and preventive replacement of wearing parts.

Component Replacement Schedule

Component	Replacement Interval	Notes
Dosing disc	6-12 months	Replace if fill weight variation increases
Tamping pins	3-6 months	Check for bending or surface wear
Vacuum filters	3 months	Replace to maintain capsule positioning
Air filter elements	3 months	Critical for pneumatic system health
O-rings & gaskets	6 months	Preventive replacement recommended
Drive belts	12 months	Replace even if not visibly worn

Electrical System Check

• Inspect all wiring connections for tightness and corrosion
• Check PLC battery status — replace if low to prevent program loss
• Verify all sensors are functioning correctly (proximity, optical, weight)
• Test emergency stop circuit and safety interlocks
• Back up PLC programs and HMI recipes to external storage

Common Problems and Troubleshooting

Problem: Incomplete Capsule Filling

• Cause: Clogged dosing disc or insufficient powder in hopper
• Solution: Clean dosing disc, check powder flow properties, ensure hopper level is maintained

Problem: Capsule Separation Failures

• Cause: Low vacuum pressure or damaged capsule segments
• Solution: Check vacuum pump and lines, inspect capsule segments for wear, verify capsule quality

Problem: High Rejection Rate

• Cause: Misaligned dosing mechanism, worn tamping pins, or incorrect fill weight settings
• Solution: Recalibrate dosing depth, replace worn pins, verify recipe parameters on touch screen

Problem: Capsule Jamming

• Cause: Damaged capsule feeding tubes or misaligned turntable
• Solution: Inspect and clean feeding tubes, check turntable alignment, verify capsule dimensions

Spare Parts Inventory

Maintain a stock of critical spare parts to minimize downtime:

• Dosing discs for each capsule size you use
• Tamping pins (set of 5-10)
• O-ring and gasket kits
• Vacuum and air filter elements
• Fuse sets and common electronic components
• Drive belts (spare set)

We supply genuine spare parts from our China factory and Germany warehouse. Contact us at [email protected] for parts orders.

Maintenance Documentation

For GMP-compliant operations, document all maintenance activities:

• Maintain a daily cleaning log signed by the operator
• Record all maintenance interventions with date, description, and technician name
• Track spare parts usage and replacement intervals
• Keep calibration records for fill weight verification
• Schedule and record annual preventive maintenance visits

Conclusion

A well-maintained capsule filling machine will serve your production for many years. Consistent daily cleaning, regular lubrication, and periodic component replacement are the foundations of preventive maintenance. By following this guide, you can minimize unplanned downtime, maintain filling accuracy, and extend the operational life of your investment.

For questions about maintenance procedures specific to your machine model, our technical support team is available via WhatsApp at +86 15152327636. For more information on choosing the right machine, see our buying guide.