Compact rotary die encapsulator for R&D, pilot production and clinical trials - 5,000 to 10,000 capsules per hour.
The RG-100 is a single-station laboratory softgel encapsulation machine built for formulation development, clinical trial batches, and small-scale contract manufacturing. With a minimum practical batch of just 500 capsules, it brings pilot-scale flexibility to your lab.
Verified factory data - not marketing estimates
Servo-controlled gear pump with +/-2% accuracy, suitable for oils, suspensions and pastes.
Minimum batch of 500 capsules for formulation screening and bioavailability studies.
Tool-free die roll swap in 15-30 minutes for multiple capsule shapes.
Standard HPMC and pullulan shell support for halal and kosher formulations.
7-inch touch screen with recipe storage and production data export.
316L stainless steel, CIP-compatible, full DQ/IQ/OQ/PQ documentation.
A contract research organization used the RG-100 to develop a fish-oil softgel for a client's Phase I study, encapsulating a 1,000 mg omega-3 emulsion in size #8 gelatin shells at a 1,000-capsule minimum batch. The +/-2% servo pump held dose uniformity across 12 pilot formulations, and the 15-minute die change let chemists compare HPMC versus gelatin shells in a single day. Because the 500-capsule floor matched the client's clinical-supply need, no material was wasted on over-production, and the open-frame design made between-batch cleaning fast enough for three formulations per shift. The small 1.2 x 0.8 m footprint fit the lab's existing cleanroom, and the documented recipe set later transferred cleanly to the client's RG-300 production line for commercial scale-up.
Our team responds within 2 hours with CIF/CFR/FOB pricing and delivery timeline.
The RG-100 laboratory model is quoted per project depending on configuration and accessory requirements. Chinese-built rotary die machines deliver 40 to 60 percent savings versus European brands while meeting the same CE, cGMP and ISO 9001 standards. Final pricing depends on automation level and documentation needs.
The single-station RG-100 produces 5,000 to 10,000 capsules per hour with a minimum practical batch of only 500 capsules. This output suits formulation development, clinical trial supplies, and pilot contract manufacturing where production flexibility matters more than raw throughput. Its compact design fits pilot labs easily.
The machine processes gelatin, HPMC (hydroxypropyl methylcellulose), and pullulan shells. Temperature, humidity, and dosing speed are adjustable per material. HPMC vegetarian capability is standard, supporting halal and kosher formulations for supplement and pharmaceutical clients. The RG-100 is ready for clean-label and plant-based product lines without additional tooling or capital investment.
Die roll changeover takes 15 to 30 minutes using the quick-release mechanism with no tools required. By swapping dies you can produce oval, oblong, round, cylindrical, and custom shapes within a 5 to 24 mm size range, or 3 to 30 mm custom.
The RG-100 handles a minimum practical batch of 500 capsules, far below the 2,000 to 5,000 capsule minimum typical of production models. This makes it ideal for R&D screening, clinical trial material, and small contract batches without wasted product. Researchers can test many formulations cost-effectively.
Yes, included at no extra cost. Our engineers provide 5 to 7 days of on-site installation, commissioning, and operator training. We also offer a free process trial at our Shanghai factory covering formulation compatibility, appearance evaluation, and parameter optimization. Remote support continues after handover.
Machines are CE certified and built to cGMP, FDA 21 CFR Part 11, and ISO 9001 standards. Documentation includes material certificates, weld records, surface finish measurements, DQ/IQ/OQ/PQ protocols, calibration certificates, and operation manuals for FDA, EMA, and Health Canada filings.
The RG-100 runs on 380V/50Hz three-phase power at 4.5 kW with a compact footprint of 1.2 m by 0.8 m. Compressed air at 0.5 to 0.7 MPa is required. Its small size fits easily into laboratory and pilot plant environments.
The RG-100 is a single-die, batch-oriented softgel line for R&D, clinical-trial and pilot runs, producing 5,000-10,000 capsules per hour from a 4.5 kW (380V/50Hz 3-phase) drive. Its servo-driven gelatin ribbon and peristaltic filling pump meter oils, suspensions and pastes at +/-2% with a 500-capsule minimum batch, so formulators can test dozens of recipes without wasting material. The die rolls and all product-contact parts are 316L stainless steel finished to Ra <= 0.4 um, and a 7-inch touch HMI stores process recipes for ribbon thickness, fill volume and tumble time. Compressed air at 0.5-0.7 MPa drives the capsule ejection and tumble conveyor, and the open-frame design gives full access for cleaning between formulations. Die changeover takes 15-30 minutes, supporting rapid iteration in early development.
The RG-100 is purpose-built for low-volume development rather than production. The RG-300 scales to 20,000-30,000 caps/hr with a 2,000-capsule minimum and a 7-inch PLC touch screen for CMO and supplement pilots, while the RG-500 reaches 40,000-60,000 caps/hr on a 10-inch HMI for industrial volumes. All three use a single-die rotary configuration with +/-2% accuracy (+-1% optional servo pump) and standard HPMC/pullulan vegetarian shells, so capability is identical - only throughput and batch floor differ. Pick the RG-100 when batches are under 50,000 capsules or formulations change weekly; move to the RG-300 for steady CMO runs above 2,000 units; choose the RG-500 only when continuous industrial output justifies its larger 2.5 x 1.5 m footprint and 1,200 kg mass.
Prepare the installation site before machine arrival. The RG-100 requires a clean, climate-controlled laboratory environment at 22-26 deg C and 30-45% relative humidity. Three-phase 380V/50Hz power at 4.5 kW with a dedicated circuit and grounding is essential. Compressed air at 0.5-0.7 MPa must be plumbed to the machine location. Ensure the floor can support the equipment weight and provides adequate clearance for operator movement on all sides.
Perform daily operational checks to maintain capsule quality and machine longevity. Before each production run, verify the gelatin or HPMC shell temperature and viscosity, inspect die rolls for surface wear, and run a short test batch to confirm filling accuracy within the +/-2% tolerance. Monitor the 7-inch HMI for any alarm flags and check the gear pump for unusual noise or pressure fluctuations. Record all readings in the production log for traceability and trend analysis.
Schedule regular preventive maintenance to maximize uptime and capsule quality. Weekly tasks include cleaning the gelatin delivery manifold with food-grade solvent and inspecting sealing surfaces for contamination. Monthly actions cover CIP cleaning cycles, O-ring and seal replacement, and verification of the servo pump calibration against the factory certificate. Annual service should include full die roll inspection, motor drive evaluation, and re-validation of the DQ/IQ/OQ/PQ documentation package to maintain regulatory compliance.
Because the RG-100 runs many different formulations, cleaning and die care drive reliability. Strip and wash the die rolls, ribbon spreader and filling pump with the approved solvent after every batch, then inspect the 316L surfaces for scoring that would mar ribbon quality. Check the peristaltic pump tubing for fatigue every 200 operating hours and replace it before it cracks - leaks are the main source of fill-weight drift. Lubricate the tumble conveyor bearings weekly with food-grade grease and verify ribbon thickness calibration against a 10-capsule micrometer check. YohoAI stocks die rolls, seals and pump tubing globally with 48-hour dispatch; keeping one spare die set on site lets a formulation switch happen during a lunch break. An annual factory service and calibration holds +/-2% accuracy and cGMP readiness.
