Gelatin Capsule Production

Capsules are a solid oral dosage form used for the delivery of medical drugs, vitamins, minerals, and other health-related ingredients. Viscosity and density of gelatin solution determine capsule shell thickness and weight, as well as flow of gelatin. Then above properties influence capsule integrity, dosing accuracy and even reliable performance in automated equipment.

Importance of Density and Viscosity Control in Gelatin Capsule Manufacturing

Lonnmeter density meter and viscosity meter outstand for wide range of density and viscosity in continuous measurements. Both inline meters are suitable for installation in tanks to monitor mixing processes and in pipelines for continuous measurement of flowing fluid. A typical gelatin solution density ranges from 1.1 to 1.3 g/cm³, and any deviation can result in brittle or overly soft capsules, leading to batch failures.

Viscosity, ideally between 25–55 mPs, governs the flow of gelatin during dipping or ribbon-forming, affecting production speed and capsule uniformity. Incorrect viscosity can cause defects like uneven shells or air entrapment, compromising dissolution rates and regulatory compliance.

Lonnmeter’s Advanced Inline Measurement Solutions

Lonnmeter’s density meter for gelatin solution, gelatin solution viscosity meter, and temperature transmitters are designed to revolutionize gelatin capsule production. These industrial process sensors provide real-time, accurate data, enabling manufacturers to maintain optimal conditions throughout the process.

• Density Meter (LONN700): Using a tuning fork principle, this inline fluid density meter measures density with ±0.002 g/cm³ accuracy. It operates reliably at temperatures up to 120°C and pressures up to 1 MPa, ideal for gelatin solutions.
• Viscosity Meter: The vibrating element technology delivers viscosity measurements with ±3.0% accuracy across a range of 1 to 1,000,000 cP, perfect for the viscous conditions of gelatin capsule production.

Feature	Lonnmeter Density Meter	Lonnmeter Viscosity Meter
Accuracy	±0.002 g/cm³	±3.0%
Operating Range	-10°C to 120°C, 1 MPa	Up to 450°C, 10 MPa (customizable)
Technology	Tuning fork	Vibrating element
Integration	4-20mA, RS485	4-20mA, RS485

Inline Monitoring vs Lab-Based Methods

Traditional lab-based sampling for density and viscosity is slow, error-prone, and disrupts production. Samples can degrade during transport, and delays in results risk entire batches. Lonnmeter’s inline solutions eliminate these challenges, offering compelling advantages:

• Instant Feedback: Real-time data allows immediate adjustments, preventing defects in production of hard gelatin capsules and soft gelatin capsules.
• Error Reduction: Inline measurements eliminate sampling errors, ensuring consistent density of gelatin solution and viscosity.
• Cost Savings: By reducing waste and labor, inline monitoring cuts costs by up to 15%, per industry estimates.
• Regulatory Compliance: Continuous data logging supports compliance with GMP and other standards, simplifying audits.
• Scalability: Inline systems support seamless scale-up, maintaining quality across batch sizes.

In contrast, lab-based methods can take hours, while Lonnmeter’s sensors deliver results in seconds, ensuring uninterrupted production and superior outcomes.

Method	Inline Monitoring	Lab-Based Sampling
Speed	Real-time (2–5 seconds)	Hours per sample
Accuracy	High (±0.002 g/cm³, ±3.0%)	Variable due to handling errors
Cost	Lower long-term costs	Higher labor and waste costs
Compliance	Continuous data for audits	Limited data points

Ensuring Consistent Capsule Quality with Process Control Sensors

Lonnmeter’s process control sensors are critical for preventing defects in gelatin capsule production. Variations in density of gelatin solution can lead to uneven shell thickness, affecting drug release, while improper viscosity causes issues like leakage or inconsistent fill volumes. These sensors ensure:

• Uniform Capsule Shells: Precise density and viscosity control produces consistent hard gelatin capsule shells and soft gelatin capsules.
• Defect Prevention: Real-time monitoring detects deviations instantly, reducing rejection rates by up to 25%.
• Optimized Production: Simultaneous measurement of density, viscosity, and temperature streamlines process control, boosting efficiency.
• Regulatory Assurance: Consistent data ensures compliance with pharmaceutical standards, protecting brand reputation.

Simultaneous Density and Viscosity Measurement in Pipelines and Tanks

Lonnmeter’s density meter for gelatin solution and gelatin solution viscosity meter enable simultaneous monitoring in pipelines and tanks, a game-changer for gelatin capsule production. Installed directly in process lines, these sensors provide continuous data on fluid density and viscosity, ensuring stability during mixing, heating, or transfer. Their ability to handle high-viscosity fluids (up to 2000 cP for density meters) and extreme conditions (up to 450°C for viscometers) makes them ideal for pharmaceutical applications. This dual measurement approach ensures precise control, reducing variability and enhancing batch consistency.

Application	Pipeline Monitoring	Tank Monitoring
Purpose	Real-time control during flow	Stability during storage/mixing
Parameters Measured	Density, viscosity, temperature	Density, viscosity, temperature
Benefit	Prevents in-process deviations	Ensures batch uniformity

Why Choose Lonnmeter for Gelatin Capsule Production?

Lonnmeter’s solutions stand out for their precision, durability, and ease of use, offering pharmaceutical manufacturers a competitive edge:

• Unmatched Accuracy: Achieve ±0.002 g/cm³ for density and ±3.0% for viscosity, ensuring superior capsule quality.
• Cost-Effective: Reduce waste and labor costs, with ROI often realized within months.
• Robust Design: Built for harsh environments, with minimal maintenance needs.
• Seamless Integration: Plug-and-play sensors connect easily to existing systems, minimizing downtime.
• Proven Reliability: Trusted by pharmaceutical leaders for consistent performance.

By adopting Lonnmeter’s technology, manufacturers can transform their gelatin capsules manufacturing process, achieving higher yields and market competitiveness.