High-capacity rotary die system for 24/7 large-scale production - 40,000 to 60,000 capsules per hour.
The RG-500 is the industrial workhorse of the RG series, engineered for 24/7 continuous production at 40,000-60,000 caps/hr. With 1,200 kg of main and auxiliary mass, it delivers the uptime and consistency demanded by large pharmaceutical and nutraceutical plants.
Verified factory data - not marketing estimates
40,000-60,000 caps/hr for uninterrupted 24/7 pharmaceutical production.
316L SS, Ra <=0.4 um, CIP-compatible, full DQ/IQ/OQ/PQ package.
+/-1% optional servo pump with flow meter for high-value actives.
15-30 minute tool-free swap across multiple capsule shapes.
10-inch touch screen with recipe management and data logging.
Standard HPMC and pullulan support for halal and kosher lines.
Our team responds within 2 hours with CIF/CFR/FOB pricing and delivery timeline.
The RG-500 produces 40,000 to 60,000 capsules per hour and is built for 24/7 continuous operation. This throughput suits large pharmaceutical plants, high-volume nutraceutical manufacturers, and contract manufacturers serving global export markets with demanding capacity requirements.
The RG-500 industrial model typically costs USD 65,000 to 120,000 depending on automation level, auxiliary equipment, and certification scope. Chinese rotary die systems provide 40 to 60 percent savings versus European brands while meeting CE, cGMP, and ISO 9001 standards.
The RG-500 occupies a footprint of 2.5 m by 1.5 m and weighs approximately 1,200 kg with auxiliary equipment. Its layout is designed for cleanroom integration with CIP compatibility and easy access to wear parts for preventive maintenance during continuous operation.
Standard accuracy is +/-2% via servo-controlled gear pumps, with an optional precision servo pump and flow meter reaching +/-1%. The system handles oils, suspensions, pastes, and semi-solids with in-process weight control and automatic rejection of off-spec capsules per USP and EP.
The RG-500 processes gelatin, HPMC, and pullulan shells with fully adjustable temperature, humidity, and dosing parameters. HPMC vegetarian capability is standard, enabling halal and kosher formulations for supplement manufacturers targeting plant-based and clean-label consumer segments worldwide.
The RG-500 uses a modular, industrial-grade design with easy-access wear parts and a preventive maintenance schedule. A 12-month warranty covers parts and labor, remote diagnostics are available, and spare parts ship within 48 hours to maximize production uptime.
The RG-500 features a 10-inch HMI touch screen with recipe management for up to 100 recipes, real-time monitoring, alarm logging, and production data export via USB or Ethernet. The PLC uses Siemens or Mitsubishi controllers for reliable pharmaceutical-grade operation.
Documentation includes material certificates (EN 10204 3.1/3.2), weld records, surface finish measurements, DQ/IQ/OQ/PQ protocols, and calibration certificates. These packages support FDA, EMA, and Health Canada submissions for pharmaceutical and nutraceutical manufacturing facilities.
Planning the RG-500 installation requires early engagement with facility and utility contractors. The RG-500 demands a pharmaceutical-grade cleanroom environment controlled at 22-26 deg C and 30-45% relative humidity with HEPA-filtered airflow. Three-phase 380V/50Hz power with dedicated switchgear and motor protection is mandatory, along with a stable compressed air supply at 0.5-0.7 MPa. The 2.5 m by 1.5 m footprint must be positioned on a level, load-rated floor with adequate space for auxiliary equipment such as gelatin holding tanks and air dryers. YohoAI provides 5-7 days of on-site installation and commissioning included in the standard contract.
Operating the RG-500 for continuous 24/7 production calls for vigilant shift handover procedures and real-time monitoring. At every shift start, verify shell material preparation status, confirm the 10-inch HMI displays no residual alarms from the previous run, and perform a 15-minute warm-up at reduced speed before reaching full production rate. Monitor capsule weight and appearance continuously; the in-process rejection system handles off-spec capsules but should be verified hourly. Log all production parameters including pump pressure, die temperature, and ambient humidity to support batch traceability and regulatory audits.
Preventive maintenance on a production machine operating around the clock requires disciplined scheduling outside peak production windows. Daily tasks include surface cleaning of the 316L stainless steel housing, visual inspection of die rolls and sealing bars, and verification of the lubrication schedule. Weekly maintenance covers the CIP cleaning cycle for the gelatin and filling manifolds, compressed air line inspection, and HMI recipe review to ensure parameters match the current product. Monthly actions include O-ring and seal replacement, die roll dimensional checks with gauge pins, and verification of the PLC control program integrity. Quarterly service should encompass servo pump recalibration, motor drive analysis, and full documentation review of the preventive maintenance log against the OQ baseline.
