Electronic Dosage Dispensing System for Softgel Capsule Filling
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Solution Overview
Problem
The existing rotary die method for producing softgel capsules lacks efficiency and accuracy in filling, with the design of precision dosing pumps and filling wedges remaining unchanged since 1935, leading to variations in filling material dosage and capsule deformation.
Innovation Solution
A dosage dispensing system incorporating a low-pressure pump, high-pressure pump, and electromagnetic coil-controlled nozzles/injectors, which ensures precise dosing and filling of softgel capsules by regulating pressure and timing through electronic controls, reducing human error and mechanical complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision dosing pumps and filling wedges are used according to the traditional rotary die method, then softgel capsules can be filled, but the design has remained unchanged since 1935 leading to variations in filling material dosage and capsule deformation
Solution Approach 1:
The patent replaces traditional mechanical piston-type dosing pumps with an electronic dosage dispensing system that uses electromagnetic actuators to control filling. This substitution eliminates mechanical wear and chamber volume variations, providing more consistent and accurate dosing while reducing capsule deformation through precise electronic control of the filling process.
Solution Approach 2:
The patent implements electronic control systems that can dynamically adjust filling parameters such as pressure, flow rate, and timing. This allows for precise control of the dosing process, ensuring consistent filling material dosage and preventing capsule deformation by optimizing parameters in real-time based on process conditions.
2Productivity
If traditional piston-type dosing pumps are used with multiple individual lines for each capsule, then filling can be performed, but the system complexity increases and maintenance becomes difficult
Solution Approach 1:
The patent employs a single electronic dosage dispensing unit that can serve multiple capsule positions through electronic control and positioning mechanisms. This multi-functional approach replaces the need for separate individual lines and pumps for each capsule, reducing system complexity while maintaining the ability to fill multiple capsules efficiently.
Solution Approach 2:
By replacing complex mechanical pump systems with an electronic dispensing system, the patent simplifies the overall structure. The electronic system uses software control and electromagnetic actuation to manage filling operations, eliminating numerous mechanical components, reducing maintenance requirements, and improving system reliability.
3Productivity
If traditional mechanical pumps and filling wedges are used, then the system can operate, but losses due to wear and chamber volume variations occur
Solution Approach 1:
The patent replaces mechanical piston pumps with an electronic dosage dispensing system that delivers precise volumes of filling material through electronic control. This eliminates mechanical wear that causes chamber volume variations and prevents filling material loss by ensuring accurate, consistent dosing without the degradation associated with mechanical components.
Solution Approach 2:
The electronic dispensing system incorporates self-diagnosis and automatic adjustment capabilities that monitor and compensate for any deviations in the filling process. This self-correcting mechanism ensures consistent dosing accuracy over time without requiring manual intervention or suffering from the cumulative effects of wear that plague mechanical systems.
4Measurement precision
If electromagnetic activation is implemented in the dispensing system, then dosing accuracy is enhanced and process monitoring is improved, but the system requires more advanced technology integration
Solution Approach 1:
The patent integrates electromagnetic actuators and electronic control systems to replace mechanical dosing mechanisms. This provides precise control over filling operations through electronic signals, enabling accurate dosage delivery and real-time process monitoring. The electronic system offers superior measurement and control capabilities compared to traditional mechanical systems.
Solution Approach 2:
The electronic dosage dispensing system incorporates feedback mechanisms that monitor filling parameters and adjust operations in real-time. Sensors and control algorithms work together to ensure accurate dosing by continuously comparing actual performance with target specifications and making automatic corrections, thereby achieving high measurement precision through intelligent control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances dosing accuracy, reduces product change time, and simplifies maintenance by standardizing dosage dispensing, minimizing losses due to wear and chamber volume variations, and enabling electronic control for improved process monitoring.
Implementation Method 1
a piston moveably arranged in the chamber of the housing for reciprocating motion between a closed position in which a flow from the inlet passage to the outlet passage is prevented and an open position in which a flow from the inlet passage to the outlet passage is allowed, the piston comprising a ferromagnetic actuation part for electromagnetic actuation of the piston by the electromagnetic coil
Data Source
AI summary
The invention relates to a rotary die device for producing soft capsules, comprising a capsule forming unit for forming a soft-capsule shell and a novel dosing unit for feeding a filling material into the capsule forming unit, characterized in that the dosing unit comprises a dispensing system that includes (a) a container defining a reservoir for storing therapeutic or non-therapeutic compositions; (b) a low pressure pump; (c) a high pressure peristaltic pump; (d) a supply line for the therapeutic or non-therapeutic compositions; and (d) one or more electromagnetically activated nozzles/injectors to fill the softgel capsules with the therapeutic or non-therapeutic compositions.