Industrial-scale encapsulation delivering 228,000 capsules per hour for high-volume pharmaceutical production lines requiring 24/7 continuous operation.
The NJP-3800 is YohoAI's flagship high-speed hard capsule filling machine, engineered for industrial-scale pharmaceutical and nutraceutical manufacturers. Its 18-station rotary platform achieves up to 228,000 capsules per hour, making it the ideal choice for facilities running continuous multi-shift production schedules and serving high-volume global markets.
Verified factory data - not marketing estimates
Eighteen-station turret provides maximum throughput per machine cycle. The optimized cam profile and precision-engineered indexing mechanism ensure stable high-speed operation without capsule damage or fill variation.
Built for continuous multi-shift pharmaceutical production. Automatic lubrication system, robust 316L SS frame, and industrial-grade PLC control handle uninterrupted operation with minimal scheduled maintenance windows.
The high-speed variant maintains the same +/-3-5% filling accuracy as lower-capacity models. Enhanced tamping pin spring systems and accelerated but controlled compression cycles preserve fill uniformity at peak throughput.
Optional vision inspection and automated weight sorting integrate directly with the rejection system. Foreign matter detection and fill-weight verification at 228,000 caps/hr meet the most stringent pharmaceutical QC requirements.
Full SCADA integration with recipe management and electronic batch records. Audit trail logging meets FDA 21 CFR Part 11 data integrity requirements for electronic records in pharmaceutical manufacturing.
Modular subassemblies enable rapid changeover of wear parts without full machine teardown. Remote diagnostics via TeamViewer/WhatsApp allow YohoAI engineers to troubleshoot and guide maintenance in real time.
A generic-pharmaceutical manufacturer in Southeast Asia deployed the NJP-3800 to consolidate three legacy fillers into one continuous line producing a 500 mg paracetamol capsule in size #0 gelatin shells. Running 210,000 caps/hr across three shifts, the plant validated +/-4% fill at commercial scale and cut labor by 60% versus the manual lines it replaced. The dual powder-plus-pellet station let the same machine add a timed-release layer for a second SKU without re-tooling, and the 18-station turret absorbed demand spikes during flu season without overtime. Integrated weight sorting removed a downstream inspection step, and the Siemens PLC audit trail satisfied the customer's FDA pre-approval inspection on the first visit. Within a year the line recovered its capital cost through labor and scrap savings.
Our team responds within 2 hours with CIF/CFR/FOB pricing and delivery timeline.
The NJP-3800 achieves a maximum throughput of 228,000 capsules per hour in its standard high-speed configuration. This makes it suitable for production facilities requiring 100 million or more capsules annually from a single machine.
Despite operating at 228,000 caps/hr, the NJP-3800 maintains +/-3-5% filling accuracy through precision-engineered cam profiles, enhanced tamping pin spring systems, and real-time weight monitoring feedback loops that adjust fill parameters dynamically.
The NJP-3800 requires standard pharmaceutical cleanroom infrastructure including 380V/50Hz 3-phase power (5.5 kW), compressed air at 0.6-0.8 MPa (200 L/min), and dust extraction. YohoAI provides full facility requirement documentation during the project planning phase.
The NJP-3800 processes both gelatin and HPMC vegetarian capsules without mechanical adjustment. The machine's automatic capsule feeding and separation system adapts to both capsule types, though a size changeover is needed when switching between them.
YohoAI provides a 12-month comprehensive warranty covering parts and labor for the NJP-3800, with remote diagnostics via TeamViewer/WhatsApp included. Spare parts ship within 48 hours globally, and lifetime software updates ensure the machine stays current with regulatory requirements.
Every unit is built to order, so a firm price comes from your specification, not from a catalogue. Six points decide it: target output per hour, product type (powder, granules, pellets, oil, cream), package format and size, voltage and frequency, certification and documentation package, and delivery terms. Send those six points and you receive a written offer with price, lead time and scope of supply within 24 hours. No obligation, NDA on request. Use the six-point specification form.
Standard delivery ranges from 30-90 working days depending on the model and configuration. Pharmaceutical GMP configurations with validation documentation packages require additional 5-10 working days. Expedited manufacturing is available for urgent orders at a 15-25% premium.
All YohoAI machines carry CE certification and are designed to meet cGMP and ISO9001 standards. Additional certifications including FDA compliance and specific food-grade standards are available depending on the product line and configuration.
The NJP-3800 is a high-density 18-station rotary filler engineered for continuous commercial output up to 228,000 capsules per hour. Its servo-indexed turret carries dual powder-and-pellet dosing groups, allowing a single machine to fill combination products - for example powder plus a timed-release pellet - without a second process step. All dosing chambers, tamping pins and product-contact surfaces are 316L stainless steel polished to Ra <= 0.4 um, and a 10-inch Siemens PLC HMI manages up to 50 recipes plus audit-trail logging for 21 CFR Part 11. The line runs on a 5.5 kW, 380V/50Hz 3-phase supply and occupies a 2.0 x 2.0 m footprint with integrated capsule feeder, powder elevator and deduster. Automatic weight sorting and vision inspection of cap sealing are available as in-line options for fully validated GMP lines.
For large-scale producers the choice narrows to the NJP-2000 and NJP-3800. The NJP-1200 (48,000 caps/hr, 10 stations) suits mid-volume nutraceutical lines, while the NJP-2000 reaches 120,000-150,000 caps/hr on 14 stations for established commercial batches. The NJP-3800 pushes to 228,000 caps/hr across 18 stations and is the right call when annual demand exceeds 600M capsules or when a single combination (powder + pellet) fill must run 24/7. All three share +/-3-5% accuracy, 5.5 kW drive and CE/cGMP/ISO 9001 certification, so the decision is purely about volume and format: the 3800's dual-dosing configuration eliminates a second machine for combo products, and its larger turret smooths output on demanding APIs. Below 150M capsules/year, the 2000 remains the cost-efficient choice.
The NJP-3800 is a heavy industrial machine requiring a robust reinforced concrete foundation with vibration isolation pads. Facility infrastructure must include a dedicated 5.5 kW, 380V/50Hz 3-phase power supply, compressed air at 0.6-0.8 MPa (200 L/min), and a dust extraction system. The 18-station turret requires precision leveling using laser alignment tools during installation. Given the machine's 24/7 production capability, plan utility redundancy to avoid production interruptions. YohoAI engineers commission the SCADA system and configure FDA 21 CFR Part 11 user access controls during the 5-7 day installation period.
For continuous 24/7 operation, the NJP-3800 automatic lubrication system must be checked daily to confirm correct oil flow to all bearing points. Monitor real-time weight monitoring feedback loops to verify fill accuracy remains within +/-3-5% at peak throughput. The advanced vision inspection system (optional) requires daily calibration verification against reference test capsules. During multi-shift operations, coordinate shift handover inspections focusing on capsule feeding consistency and rejection system accuracy. The modular subassembly design enables rapid changeover of wear parts without full machine teardown.
Scheduled maintenance every 500 operating hours includes cam profile wear assessment, enhanced tamping pin spring inspection, and turret bearing condition review. The modular maintenance design allows subassembly replacement reducing planned downtime significantly. Remote diagnostics via TeamViewer/WhatsApp enable YohoAI engineers to guide on-site technicians through fault isolation and repair procedures. Annual comprehensive maintenance should verify the full SCADA audit trail integrity, confirm FDA 21 CFR Part 11 compliance for electronic records, and validate the complete electronic batch record auto-logging system.
At 228,000 caps/hr the NJP-3800 demands a structured preventive program to protect uptime. A daily pre-shift check should confirm capsule feeder alignment, dosing-pin spring tension and the automatic reject rate using a 30-capsule weight sample on an analytical balance. The most frequent root causes of drift are worn dual-dosing chamber seals and pellet-needle misalignment, both caught by the 500-hour inspection. Because the 3800 runs 24/7 in many plants, YohoAI recommends a rotating spare-parts set - dosing discs, seals, alignment bushings, cam followers - held on site with 48-hour global dispatch, plus a quarterly factory calibration of the servo turret. An annual preventive-maintenance kit and vibration analysis of the main drive typically hold OEE above 90% and keep validation documentation audit-ready.
