Customer Background
Our client is a health supplement manufacturer based in Bulgaria, specializing in vitamin and mineral capsules. With the launch of a new production project, the client aimed to build a highly automated production line to improve efficiency, ensure accuracy, and reduce labor costs.
Customer Requirements
The client required a complete solution covering the entire process from capsule production to final bottle packaging. Key requirements included:
- Capsule filling for vitamins and minerals
- Accurate counting and filling into bottles
- Compatibility with five different bottle types
- Automatic insertion of desiccants into each bottle
- Automatic capping and screw capping
- Induction sealing with aluminum foil
- High level of automation, ideally operated by only one worker
Our Solution
After a detailed analysis of the client’s needs, we provided a customized fully automatic production line.
First, we carefully reviewed all bottle specifications to ensure that one production line could be fully compatible with different bottle sizes and formats.
Based on the required production capacity, we selected the appropriate capsule filling machine. Since the client’s packaging standard was based on the number of capsules per bottle (not weight), we recommended a counting machine as the core feeding system. This ensures high precision and consistency for each bottle.
We then integrated all equipment into a seamless automated line, including:
- Bottle unscrambler
- Capsule filling machine
- Counting machine
- Desiccant inserting machine
- Cap placing machine
- Screw capping machine
- Aluminum foil sealing machine
Workflow Overview
- Bottles are loaded manually into the bottle unscrambler
- Bottles are automatically oriented and conveyed
- Capsules are produced and transferred to the counting system
- Precise counting ensures the exact number of capsules per bottle
- Desiccants are automatically inserted
- Caps are placed and tightened
- Bottles are sealed with aluminum foil
The entire system is highly integrated and runs continuously with stable performance.
Final Results & Advantages
- Fully automated process with minimal manual intervention
- Only one operator required, significantly reducing labor costs
- High counting accuracy, ensuring product consistency
- Flexible compatibility with multiple bottle types
- Improved production efficiency and hygiene standards
- Reliable and stable operation for long-term use
Conclusion
This project demonstrates our ability to deliver customized, efficient, and scalable packaging solutions for the health supplement industry. By combining precise counting technology with full-line automation, we helped our client successfully upgrade their production process and achieve higher operational efficiency.