{"id":2599,"date":"2024-06-22T11:27:09","date_gmt":"2024-06-22T11:27:09","guid":{"rendered":"https:\/\/gardenia.axiomthemes.com\/?p=2599"},"modified":"2025-02-04T22:43:10","modified_gmt":"2025-02-04T17:13:10","slug":"building-the-perfect-foundation-for-your-future","status":"publish","type":"post","link":"https:\/\/hallmarkglobal.in\/pinbars\/building-the-perfect-foundation-for-your-future\/2024\/","title":{"rendered":"Choose Zero Rejection"},"content":{"rendered":"\t\t
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Part I: Loose & Non-Separating Capsules, Missing Caps, Double Caps<\/strong><\/p>\n

Capsule Rejections are the worst nightmares for the Production Heads.<\/p>\n

Causes could be very many, related to \u00a0inconsistencies in Gelatin quality, Viscosity, Temperature of the Gel, Moisture content, Plasticizer type & quantity, improper Machine settings, etc. Manufacturers are able to identify and handle these, almost immediately.<\/p>\n

However, if the cause lies in the Pinbars, the solutions is not quite simple.<\/p>\n

Your Capsules will bear the brunt of it for years.<\/p>\n

As pinbar manufacturers, our goal is to supply pinbars that performs uninterrupted, seamless operation from start to finish.<\/p>\n

This article views the likely ways Pinbars can influence the Capsule manufacturing process and the resultant capsules.<\/p>\n

Defects are typically generated during initial machine\u00a0settings, inconsistencies in raw material, process-related issues, mechanical problems or flaws in pin design. And are detected during either of the following stages: During pre-sorting , when traveling through ATS, \u00a0during Capsule aeration and cleaning stage or during Inspection, manual or on Scanners.<\/p>\n

Broadly, rejections that can be partly related to Pinbar design are :<\/p>\n

1. Loose cap\/body, Double caps, missing caps<\/p>\n

2. Non-separation<\/p>\n

3. Telescopy<\/p>\n

4. Ovality of capsules<\/p>\n

5. Dent after locking<\/p>\n

Loose Cap\/Body & Non-Separations, Missing Caps, Double Caps:<\/strong><\/p>\n

Proper Capsule separation is an integral part of Capsule filling operations.<\/p>\n

The most common hurdles faced in this stage are rejections and downtime. The cause are poorly fitted Cap & Body shells that behave like married couples; sticking together so tight that they cannot be separated when required and drifting apart when needed to stay together. The Non-separated and the Loose Capsules.<\/p>\n

Mr Steve Lee in his Blog titled \u201cCapsule Separation: 5 Steps to Reduce Waste and Downtime\u201d dtd 28-Mar-2022 , rightly says,<\/p>\n

Quote<\/em><\/p>\n

\u201cThe expectations for empty capsules today have never been higher. Encapsulating powder, pellets, tablets and liquids, filling machines operate at speeds of up to 400,000 capsules per hour. When considering capsule separation, the window of opportunity to achieve proper seating and separation of the capsule is a fraction of a second. At these rates, both <\/em>the capsule<\/em><\/strong> and <\/em>the equipment<\/em><\/strong> should be at their best.\u201d<\/em><\/p>\n

Unquote<\/em><\/p>\n

Here we look at the Pinbar aspects that influence the fitting of the Cap and Body shells.<\/p>\n

Variation in Pin diameters:<\/em><\/p>\n

The Pin diameters are maintained within a close tolerance of +\/- 5 Microns. Which means there would be a maximum difference of 10 microns between the Cap and the Body diameters.<\/p>\n

Pin Diameters, if not strictly controlled<\/em> within this range, would result in problems of non-separation or Loose capsules. Caps with largest diameters when paired with lowest diameter Body shells will result in loose capsules and vice versa for non-separations.<\/p>\n

Loose Cap may lodge onto another Body shells leading to Missing caps & Double caps<\/strong>. Higher the variation in diameters, higher the inconsistencies and rejections.<\/p>\n

Hallmark<\/strong> employs rigorous quality control measures, including comprehensive diameter inspections at every stage of the manufacturing process. Advanced online inspection systems are integrated into our production lines to identify and segregate non-conforming pins in real time. There is an immediate adjustments to manufacturing processes, ensuring consistent product quality and adherence to stringent standards.”<\/p>\n

Hallmark employs rigorous quality control measures, including comprehensive diameter inspections at every stage of the manufacturing process. Advanced online inspection systems are integrated into our production lines to identify and segregate non-conforming pins in real time. There is an immediate adjustments to manufacturing processes, ensuring consistent product quality and adherence to stringent standards.”<\/p>\n

This ensures 100% compliance to specifications and six sigma precision. Data are shared through WiFi to main Servers for Analytics and Record keeping.<\/p>\n

Opening and Closing Forces in Semi-locked and Locked Positions:<\/em><\/p>\n

The other important factors influencing fitment of capsules are Profiles of Pre-lock dimples and locking grooves. These determine the fitment forces of the Capsules in Semi-locked and Final locked positions.<\/p>\n

Lower \/ higher than standard range would result in Loose \/ Non-separated Capsules.<\/p>\n

We at Hallmark<\/strong>, having a Design team with an experience of four decades have developed considerable insights into this aspect.<\/p>\n

We have developed a customized software that predicts the Opening and Closing forces at play in the Semi-locked and fully Locked positions.<\/p>\n

Additionally, we have a fully equipped lab that can measure the various parameters governing fitment of Hard capsules. This allows us to thoroughly test the forces of the Capsules made during Trials and modify Pinbar design to effect desired results in Capsule performance.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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Sample Report - From the HALLMARK ADVANCED TECHNOLOGY PVT LTD<\/p>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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Our customers are absolutely satisfied with the fitment of Capsules made from our Pinbars, including the new Companies making Capsules for the first time. They have reported zero rejection due to poor fitment.<\/p>\n

In this Article, we have primarily dealt with the fitment aspect. We thank you for your time.<\/p>\n

There are more aspects on Capsules Rejections which would like to address in our next Newsletter. In the meantime, we invite your sincere view points. It will help us deliver a better Product each time.<\/p>\n

\u2026\u2026\u2026\u2026\u2026\u2026\u2026\u2026\u2026.<\/p>\n

#Hallmark #Worldclass #Pinbars #Capsule Molds #Accuracy #Precision #Design #Branding #InternationalQuality #Empty Capsules #HPMC #GelatinCapsules #HardCapsules #Capsuledefects #Capsule rejections<\/p>\n

\u00a0<\/p>\n

Healthcaps India Ltd<\/a> CapsCanada<\/a> Capsule Wecaps<\/a> GoCaps GmbH<\/a> Capsugel<\/a> CapsulCN<\/a> Farmac\u00e1psulas- Fabricante de c\u00e1psulas vac\u00edas<\/a> Nashmir Capsule<\/a> Lefancaps International<\/a> GS Capsule<\/a> Natural Capsules Limited<\/a> JEDCO International for Pharmaceuticals<\/a> Shaanxi Genex Bio-Tech Co., Ltd BIO-CAPS INDIA LIMITED<\/a> GDL CAPSULE<\/a> Natural Capsules Limited<\/a> Matthew Knopp<\/a> Dr.Jnanadeva Bhat<\/a> Sainty International Group<\/a> Sensum<\/a> IpharMachine<\/a> Hangzhou Qogori Co.,Ltd. (K2 TECH)<\/a> Kranthi V<\/a> Steve Lee<\/a><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

Part I: Loose & Non-Separating Capsules, Missing Caps, Double Caps Capsule Rejections are the worst nightmares for the Production Heads. Causes could be very many, related to \u00a0inconsistencies in Gelatin…<\/p>\n","protected":false},"author":1,"featured_media":58030,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[145],"tags":[186,189,188,184,185,187],"class_list":["post-2599","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-standard","tag-construction","tag-fabric","tag-gas","tag-industry","tag-news","tag-oil"],"_links":{"self":[{"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/posts\/2599","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/comments?post=2599"}],"version-history":[{"count":7,"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/posts\/2599\/revisions"}],"predecessor-version":[{"id":58031,"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/posts\/2599\/revisions\/58031"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/media\/58030"}],"wp:attachment":[{"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/media?parent=2599"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/categories?post=2599"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/hallmarkglobal.in\/pinbars\/wp-json\/wp\/v2\/tags?post=2599"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}