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GKF 2500 | GKF 2500 L | GKF 2500 ASB IPK | GKF 2500 ASB 100% | GKF 3000

GKF 2500 – Capsule Filling Machine
Packaging Technology

2 | GKF 2500 – Capsule Filling Machine

Modularity, Flexibility and
Economical Operation in Capsule Filling
Whichever products you would like to fill – powders, pellets, tablets,
liquids, micro-dosing or combinations, the GKF 2500 offers the correct
solution in the high speed production range

The GKF 2500 is a versatile and flexible

The GKF 2500 ASB IPK with in-process control

machine. This provides a high versatility of fill

provides you with weight control via statistical

options with varying product tapes. Even

evaluation, with documentation of the sample,

complex products with varying fill parameters

day, and batch data.

can easily be processed. Thanks to the modular
design of this capsule filler, the machine can
be changed-over in a minimal amount of time.

Ergonomical and Secure Handling

Machine control via the touch-screen HMI is

With a focus on ergonomics and cleanability, our

especially user-friendly. The control of the

engineers developed a machine that minimizes

machine and measurement data collection are

change-over and cleaning times and therefore

handled via an industrial PC. All production data

maximizes productivity. The cGMP-compliant

is also saved and managed on the industrial PC.

production cabin ensures easy accessibility and

The windows-based software complies with the

user-friendly operation and cleaning. Likewise,

data security guidelines of 21 CFR part 11.

machine sub-assemblies are quickly and easily
exchangeable, for example, during format

Quick and Easy Operation

change-overs.

The machine table-top is seamlessly machined
as one piece. This allows for large-radius contours without undercuts, according to proper
GMP design. Furthermore, only FDA-approved

GKF 2500 – Capsule Filling Machine | 3

The design of this capsule filler provides for quick and complete
cleaning, as well as efficient change-overs. Thereby, the machine fulfills
all modern cGMP requirements. The PC-based control system also
allows for automatic data-logging of all production processes.
Therefore, the GKF 2500 sets new standards in pharmaceutical security.

The GKF 2500 ASB 100% is equipped with an

The GKF 3000 is based on the successful

integrated checkweigher. Every capsule produced

GKF 2500 and sets a new benchmark in the

on the capsule is individually and precisely

pharmaceutical industry with its output of

weighed. Only capsules with a weight within

175,000 capsules per hour. This machine

the pre-set tolerances are accepted. Over- and

is reliable, low-maintenance, and provides

underweight capsules are rejected.

production security.

materials are used. The maintenance-free main

As the fastest tamping pin principle machine on

drive allows for quiet operation of the machine,

the market, the GKF 3000 offers precise dosing

reduces wear, and extends the machine lifetime.

with minimal product loss. Powder or pellet
products are gently filled and even products
with varying fill parameters can be optimally
filled via height-adjustable dosing disks. A spe-

▶ Highly accurate dosing

cial seal separates the production and drive

▶ Simple operation

cabin, thereby protecting the product from

▶ cGMP-compliant design

foreign contaminants.

▶ Flexible dosing possibilities
▶ Low-maintenance operation
▶ Data security
▶ Reliability
▶ Optimal accessibility

4 | GKF 2500 – Capsule Filling Machine

Functional Description
and Dosing Options
Functional Description

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1

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12

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11

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10

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9

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8

1

Capsule orientation and separation

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Open for optional pellet or tablet station

2

Capsule orientation and separation

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Capsule closing with capsule body scanner (ASB function)

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Capsule cap scanner (ASB function)

10 Individual capsule ejection (ASB function)

4

Open for an optional pellet station 1

11 Individual capsule ejection (ASB function)

Dosing station for powder/pellets via

12 Segment cleaning with compressed air (ASB function)

5

fixed or height-adjustable dosing disk,
iquid filling station or micro-dosing station
6

Open for optical pellet station

7

F
aulty-capsule rejection

No ASB function available on the GKF 3000

1
2

Not on the GKF 3000
Optional pellet station on the GKF 3000

GKF 2500 – Capsule Filling Machine | 5

Powder/Pellets
Dosing station with
patented slidegate
technology for filling
of powder or pellets.

Micro-dosing 1
Highly precise
dosing of small
powder volumes
(e.g. Inhalation
products).

Pellets
The pellet station
offers gentle filling
and is ideally
suited for use in
combination filling.

Tablets 1/Micro-tablets 1
A defined number of tablets
can be filled precisely via
the tablet station

Liquids 1
The servo-controlled
liquid pump offers the
ideal filling technology
for a broad viscosity
spectrum.

Combinations
Numerous product
combination fills
are possible on the
GKF 2500-series
thanks to its modular
design.

1

Not on the GKF 3000

Custom Solutions
The GKF 2500-series provides
the opportunity to customize
filling solutions, thanks to its
open platform.

6 | GKF 2500 – Capsule Filling Machine

Optimal Productivity
via Quality Control
Reliable Operation via Automatic

infeed. A repeated missing capsule in a

Trouble-Shooting

particular segment bore is recognized by the

The automatic trouble-shooting feature auto-

consecutive fault function. Deformed capsules

mates your production and reduces your down-

in the capsule magazine are blown out via

time. The calibration strip in the empty capsule

individual compressed air lines and routed to

sorting magazine ensures that deformed or

a separate deformed capsule container.

damaged empty capsules are removed even
before the filling station.

The capsule body scanner recognizes incomplete
capsules during capsule closing. Therefore,

The mechanical capsule cap scanner determines

incomplete capsule portions do not make it into

if there are blockages in the empty capsule

the good capsule production container.
The capsules that have been determined to be

ASB function

faulty are individually rejected at the 18 capsule
ejection flaps. The segment cleaning station with
compressed air nozzles loosens sticky products
and capsule fragments from the segment bores
and reliably vacuums them away. This station
ensures the cleaning of all the segments for the
next filling cycle.

GKF 2500 – Capsule Filling Machine | 7

The GKF 2500-series guarantees optimal productivity and pharmaceutical security
in capsule filling with it’s automatic trouble-shooting features (ASB), in the GKF
2500 ASB, GKF 2500 ASB IPK or GKF 2500 ASB 100% versions.

GKF 2500 ASB 100% with

fill weight. If a capsule is outside the tolerance

Online Weight Control

range, it is automatically rejected. The incident
will then be documented in the production

Beyond the advantages of ASB, the integrated

report.

weighing system offers you a secure and
documented production process.
The highly accurate weight-control feature
automatically controls fill weights with its

▶ Out-of-tolerance capsules are
automatically rejected

pneumatic adjustment of the tamping pin

▶ Reduction of machine downtimes

pressure. Thereby, it is ensured that the

▶ Lights Out Operation

desired fill weight is maintained within the

▶ The capsule filling machine can be

specified tolerance range for the entire
production process.

operated with or without the 100%
checkweigher
▶ The checkweigher can be operated

The analysis software calculates an average
fill weight from the checkweigher results
and compares this average to the theoretical

with or without the capsule filler

8 | GKF 2500 – Capsule Filling Machine

No Risk – Weighing Technology
of the Highest Quality
GKF 2500 ASB IPK with In-Process Control
Filled capsule samples are individually removed
from the filling process and weighed at predefined intervals. The sampling process can be
completely defined by the user. The analysis
software calculates an average fill weight from
the checkweigher results and compares this
average to the theoretical fill weight. If the
average weight of several samples exceeds
the tolerance limit, the tamping pin pressure
is automatically adjusted by the pneumatic
tamping pin adjustment function. The incident
will then be documented in the production
report.
After the sample capsules are weighed they
are collected in a separate container. The
individual weights are indexed according to
their position in the segment. The scale will
tare itself after every capsule it weighs.

GKF 2500 – Capsule Filling Machine | 9

GKF 2500 with KKE 2500

Functional Description 100% Check Weighing

Accurate weighing method
The Bosch patented “hanging weigh cell”

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principle safely weighs all capsules while

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avoiding dust or residue build up within the
weighing cell. In addition the weigh cell
design eliminates electrical interferences

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4

such as electrostatic fields.

5

Dependable production documentation
Data for the entire production run is stored
and digitally evaluated by the user friendly
operating system. All of the data available

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on the system can be saved on the integrated

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6

1 Capsule Hopper

DVD Burner or transferred to an external

2

Insertion Pusher

system via the USB port.

3

Magazine

4 Calibration bar

Size changeover in < 1 min

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5 Size Plate

The ergonomic design, which sucessfully

6 Separating Flaps

meets cGMP requirements permits a size

7 Transport Finger

changeover in less than one minute. All

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change parts can be quickly disassembled

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Weighing Cell

9 Transport Wheel

without tools, allowing rapid cleaning with

10 Discharge Flap

no residues.

Easy, fast cleaning
Due to the hermetic separation of the
production and drive section (balcony
design) there is no contamination of
the product and the machine is easy
to clean.
Standard automatic trouble shooting
(ASB)
The ASB function automatically detects
and ejects deformed capsules, helping
to eliminate unnecessary downtime and
increase productivity.

10 | GKF 2500 – Capsule Filling Machine

Technical Data
Machine cycles
 Max. 140 cycles/min.
Electrical connection
 400–440 V, +/- 10%, 50 Hz,
400–460 V, +/- 10%, 60 Hz 3 ph/PE
 Special voltages
 10 kVA total

Standard equipment
 Base machine with integrated electrical
cabinet and built-in HMI
 Machine control: industrial-PC
 Empty capsule hopper with minimum
and maximum level control sensors
 Adjustment of the dosing disk height
 Capsule closing station with concave
closing pins
 Cleaning station with compressed air
nozzles and vacuum suction

Maximum amperage
 16A
Vacuum pump electrical connection
 1,85 kW, 50 Hz, 2,2 kW, 60 Hz
Vacuum requirement
 50 m3/h bei -250 mbar
Utility Connections
 Compressed air supply Ø 13 mm
 Vacuum pump connection Ø 30 mm
 Dust collector connection 2 x Ø 70 mm
 Vacuum pump electrical connection
 Jogging cable connection
 Dust collector electrical connection
 Main electrical connection

1
2

optional on GKF 2500 and GKF 3000
Not on the GKF 3000

Formats
 Capsule format set for all standard
capsule sizes, 00 to 5, D B
Options
 High-adjustable dosing disk

2500

2500 ASB

Output (max. capsules/h)

150,000

Segment bores

18

Compressed air consumption
(m³/h at 5 bar)

2

200 | 220 | 380 | 400 V
50 Hz, 2 x 2,2 kW

220 | 380 | 400 | 460 | 480 V
60 Hz, 2 x 2,55 kW

Dust-collector air flow volume

20 m³/min, open suction

Weight (kg)

ca. 1,700

GKF 2500 / GKF 3000

2500 ASB IPK

150,000

Dust-collector electrical connection

2500 ASB 100%

3000

150,000

150,000

175,000

18

18

18

21

2

4

20

2

ca. 3,300

ca. 1,700

ca. 2,000

ca. 2,200

2762

2072

2027
2220

Accessories
 Vacuum pump for capsule separation
 Dust collector
 Automatic powder feeding
 Empty capsule feeder
 Capsule polisher
 Metal detector
 Distribution system

2466

GKF

Filling options:
 Powder filling station
 Pellet filling station
 Liquid filling station²
 Tablet filling station²
 Micro dosing station²

Infeeds
 Powder infeed – Triclamp
DN 150, DIN 32676
 Pellet/Tablet infeed – Triclamp
DN 100, DIN 32676
 Empty capsule infeed – Triclamp
DN 100, DIN 32676

1389

2762

GKF 2500 – Capsule Filling Machine | 11

GKF 2500 ASB

2762

20272027
2027
20722072
2072

24662466
2466

2762
2762

2220

1389

2220
2220

1389
1389
2762

GKF 2500 ASB IPK

20272027
2027
20722072
2072

24662466
2466

2762
2762

2320

1389

2320
2320

1389
1389

2762

24662466
2466

2762
2762

20272027
2027
20722072
2072

23432343
2343

GKF 2500 ASB IPK 100%

3061
3061
3061

1389
1389
1389

Robert Bosch GmbH
Packaging Technology
Product Division Pharma Solid
Stuttgarter Straße 130
71332 Waiblingen
Germany
Phone +49 711 811-0
www.boschpackaging.com

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packaging@bosch.com