tablet counting and filling machine provides precise tablet dispensing through an automated process. Its basic operations are divided into four stages: vibration feeding, optical counting, error elimination and container filling. The TFM 5200 model of Bosch, Germany, for example, has a processing speed of 600 bottles/minute (30 pieces per bottle), a counting accuracy of 99.99% (error ±0.1 pieces/bottle), and a power consumption of 4.5kW, which is 300% higher than that of semi-automatic equipment. The machinery uses a vibrating disk (amplitude 0.5-2.0mm, frequency 50 Hz) to individually list the tablets, measures the number in real time by an photoelectric sensor (sampling frequency 1,000 times/SEC), and detects fragments or shaped tablets with the help of an AI vision system (e.g., the Keyence CV-X series) (recognition rate of 99.9%). The rejection rate is controlled below 0.01%.
With respect to technical specifications, tablet counting and filling machine filling accuracy is influenced by material properties. For example, disk tablets (8 mm diameter, 3 mm thickness) have a fluidity Index (Carr Index) of ≤15 and can be fed stably at a rate of 120 pieces per second using a screw feeder; For special shapes (like triangles, Carr Index≥25), vibrating disc should be inclined to 25°, speed should be reduced to 80 pieces per second, and 0.3% silica flow aid should be added to reduce the likelihood of clogging (from 12% to 3%). Cognex’s 3D vision system checks the Angle of stacking on the tablet real-time (accuracy ±0.5°) and adjusts the dispensing path with a servo motor (reaction time 0.1 seconds), ensuring that the filling weight deviation to ≤±1.5% (USP requirement ±5%).
Economically, the fully automatic tablet counting and filling machine is estimated to be priced at about $200,000 – $500,000 for the first instance, but payback is acceptable. Ever since the arrival of Pfizer, along with the Italian MG2 ML-100 model, the line output capacity has increased from 480,000 bottles to 1.5 million bottles, labor charges reduced by 85% (10 people per shift to 1.5 people), and ROI was reduced to 14 months. Maintenance cost of equipment is around 5% of annual operating expenses (about $12,000), crucial components such as photoelectric sensors last for 50,000 hours, and the vibration disk wear-resistance layer (tungsten carbide) withstands 1 billion tablet frictions with a replacement period of 5-8 years.
Industry transformation results from technological innovation. In 2023, the Uni-300 model with Internet of Things (IoT) integration was released by Uhlmann, predicting the threat of failure (95% accuracy) and reducing downtime by 70% through real-time monitoring of vibration disk temperature (±1 ° C) and motor load (±2%). Its AI algorithm optimizes feeding parameters based on 100,000 sets of historical data to enhance the rate of processing shaped slices by 40%. In addition, the modular design allows for rapid bottle changing (10 mL to 100 mL), and the changeover time is reduced from 30 minutes to 5 minutes to meet multi-specification production demands.
Compliance with regulations is a key consideration. FDA GMP requirements for the sterility of the filling area to ISO Level 5 (particles ≤3,520/m³), equipment should be equipped with a laminar flow hood (wind speed 0.45 m/s±10%) and electrostatic eliminator (residual voltage ≤50 V). For example, Catalent uses the CC-120 model of Bausch+ Strobel in Germany to produce the COV oral drug, which uses an online weight system (± 0.1g) to ensure the weight of each tablet to meet the USP requirement (±3% deviation), and the chances of passing the FDA audit are increased from 88% to 99%.
Application cases demonstrate efficiency. Indian pharmaceutical company Sun Pharma uses a domestic semi-automatic model ($80,000) to produce antimalarial drugs at 120 bottles per minute with an error rate of 0.1% and saves $240,000 in labor costs every year. Eisai Pharmaceutical of Japan placed a fully automatic line (rate 400 bottles/min) to produce Alzheimer’s drugs, reducing the cost of one pill from $0.05 to $0.02, and increasing its market share by 15%. The global tablet filling machine market size will be 3.4 billion US dollars in 2028, of which intelligent models (combined AI and IoT) account for more than 60%, urging the pharmaceutical industry to realize the “zero defects” goal.