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LFA SACF 25 User Manual

Semi-automatic capsule filler
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SACF 25
®
Semi-Automatic Capsule Filler
User Manual
We don't just sell machines—
we provide service.

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Summary of Contents for LFA SACF 25

  • Page 1 SACF 25 ® Semi-Automatic Capsule Filler User Manual We don’t just sell machines— we provide service.

  • Page 2: Copyright Notice

    Copyright Notice © LFA Machines Oxford Limited, published in 2022 by LFA Machines Oxford Limited 2022. Registered in England and Wales, company number 08428898, registered office for service Demar House 14 Church Road East Wittering, Chichester, West Sussex, PO20 8PS.

  • Page 3: Important Safety Information

    • Wear a beard net if needed (food grade ensure that it complies with all local laws and industry accepted safety regulations. products only). If you require guidance on the installation of the machine or conducting a safety assessment, please contact LFA Machines.

  • Page 4: Symbols

    Proposition 65 warning label. Warning for Explosive Material This machine is not explosion proof. LFA recommends that you test your materials' explosivity before running them through this machine. If your materials are indeed explosive, do not use them with this machine.

  • Page 5: Table Of Contents

    Preface Training On-Site/Off-Site Training Training via Video Chat/Phone LFA Articles LFA Videos Installation Tools and Materials Needed Positioning the SACF 25 ® Controls Settings and Adjustment Maintenance General Maintenance Prescriptions Lubrication Dismantling for Repair and Replacement Wear Parts and Causes of Damage...

  • Page 6: Sacf 25 ® Components

    SACF 25 Components ® 1. Capsule Hopper 11. Capsule Sealing Plate 2. Capsule Sewing Mechanism 12. Powder Hopper 3. Control Panel 13. Auger Housing 4. Capsule Discs 14. Capsule Filling Start Button 5. Base 15. Capsule Hopper Lid 6. Wheel 16.

  • Page 7: Preface

    ® has been designed for fast production with an emphasis on safety and ease of use. The purpose of this document is to support your understanding of the SACF 25 ® ’s components, features, functions, and design. With this manual, you will be able to successfully operate and maintain your SACF 25 ®...

  • Page 8: Training

    Using an online video chat system, an LFA technician can interact face-to-face with you and assist with your understanding of the machine. Or, if you prefer, LFA can provide training via phone for all customers who call the office. To set up a training, call or email your local LFA office:...

  • Page 9: Installation

    • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) The Appropriate Workstation for the Machine The floor on which the machine is to be placed must support the SACF 25 ® ’s 330 kg (about 727 lbs) weight.
  • Page 10 The shipping crate will contain the following: 1. The SACF 25 ® 2. The Tooling (already installed)
  • Page 11 3. Toolkit including: • Grease gun • Powder scraper • Pliers • Adjustable screwdriver • Cleaning brushes • Plug for air compressor (optional) • Replacement lower bolt • Hook to remove stuck capsules 4. Vacuum Pump and Filter...
  • Page 12 Unpacking the SACF 25 ® Tools Needed • Crowbar • Hammer • Socket wrench set Instructions 1. Pry open each side of the shipping container with a crowbar and hammer and remove them. 2. Remove the Filter, Vacuum Pump, Toolkit, and Power Cable.
  • Page 13 3. Remove the bolts on the shipping container's base with a socket wrench. 3.1 Note: Keep the nuts, bolts, and the shipping container’s base in case you need to move or relocate the machine.

  • Page 14: Positioning The Sacf

    SACF 25 ® Because of its 330 kg (around 727 lbs) weight, LFA does NOT recommend carrying the machine manually but rather with an forklift. At least two people should be involved (one operating the pallet jack and one stabilizing the machine) in removing the machine from the shipping container and placing it in the workspace.
  • Page 15 4. Place the pallet jack underneath the machine and lift it. 5. Remove the two woodblocks from the shipping container's base. 6. Pull out the shipping container's base from under the machine. 7. Carefully lower the pallet jack until the wheels make contact with the floor. 8.
  • Page 16 10. Place the Filter on top of the Vacuum Pump. 10.1 Note: Use plumber's tape around the threaded part of the Vacuum Pump to ensure a good seal to reduce pressure loss. 11. Plug in the Vacuum Compressor and main power cable.
  • Page 17 12. Plug in the Vacuum Pump's hose and tighten it with a flathead screwdriver. 13. Insert the 8 mm push fit airline.

  • Page 18: Controls

    Controls Basic Components A description of the principal components follows: • The Capsule Hopper holds the empty capsules. • The Capsule Sewing Mechanism aligns the capsules in the correct position with a magazine and inserts them into the Capsule Discs, which separate the capsule caps and bodies with a vacuum pump.
  • Page 19 Control Console 1. Switch between Fill Count, Delay Filling, and 5. Switch from automatic mode to jog mode Capsule Separating settings 6. Cut off machine in emergency 2. Lower the setting 7. Operate the Auger and filling arm 3. Raise the setting 8.
  • Page 20 SACF 25 ® Process The basic mechanism of the SACF 25 involves inserting the capsules into the Capsule Discs, ® separating the capsule halves, filling the capsule bodies, and sealing/ejecting the capsules. Inserting Capsules into the Tooling Capsules are poured into the Capsule Hopper, which then distributes them to the Capsule Sewing Mechanism.
  • Page 21 Tools and Materials Needed • Empty capsules • Raw material formulation • Fully assembled SACF 25 ® • Powder scraper (comes with machine in SACF 25 ® Toolkit) • Receptacle for filled capsules • Safety goggles • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) •...
  • Page 22 5. Press the Vacuum Pump button. 6. Press the Capsule Sewing button to insert the empty capsules into the Capsule Discs. WARNING: To prevent any potential personal injury, keep hands and fingers away from the Capsule Sewer during operation. 7. Rotate the Capsule Discs counterclockwise for a few rotations to ensure that the capsule caps and bodies are separated once the machine has finished automatically sewing the capsules.
  • Page 23 10. Pour the dry materials into the Powder Hopper. 11. Press the Filling button to start the Auger. 11.1 Note: The Auger will automatically stop once it has filled each capsule body. 12. Remove the excess powder with the powder scraper.
  • Page 24 13. Place the top Capsule Disc back onto the bottom one. 14. Align the Capsule Discs with the Capsule Ejection Disc and insert them on it. 14.1 Note: Ensure that holes and pins are properly aligned. 15. Pull down the Capsule Ejection Disc's cover.
  • Page 25 16. Press on the air pressure mechanism's food pedal to seal the filled capsules. 16.1 Note: The pedal is located at the bottom left of the machine. 17. Push the Capsule Discs against the Capsule Ejection Disc to eject the filled capsules.

  • Page 26: Settings And Adjustment

    Settings and Adjustment The SACF 25 ’s settings can be adjusted. Tuning the machine can help with changing the capsule ® dose and machine operation. Speed Adjustments The SACF 25 ® has three variable frequency drivers (VFDs) for capsule sewing speed, auger speed, and capsule fill speed.
  • Page 27 Auger Fill Amount Time Whenever the Capsule Disc's rotation speed is decreased, the Auger fill amount time has to be increased. This will make sure that there is enough time for the Capsule Disc to fully rotate under the Auger. Tools and Materials Needed •...
  • Page 28 Capsule Sewing Amount The amount of capsules to be fed into the Capsule Discs needs to be adjusted any time the Tooling is changed. Tools and Materials Needed • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) •...
  • Page 29 Note: Wear latex/rubber gloves (and appropriate food grade attire if applicable) during this process. 1. Run the machine to determine the adjustment. WARNING: To prevent any potential personal injury, ALWAYS push the SACF 25 ® Emergency Stop button when adjusting the Capsule Sewer alignment.
  • Page 30 4. Remove the two bolts on the Capsule Hopper with an Allen key. 4.1 Note: Ensure to support the weight of the Capsule Hopper when removing the bolts. 5. Remove the Capsule Hopper from the machine. 5.1 Note: Be careful when removing the Capsule Hopper. The Capsule Magazine is fragile, so ensure not to knock it with the Capsule Hopper.
  • Page 31 6. Loosen the Capsule Disc Mount with an Allen key. 7. Insert the Alignment Tools inside the Capsule Discs and front teeth section.
  • Page 32 8. Adjust the Capsule Disc Mount and Capsule Discs so that the Alignment Tools rotate freely inside the front teeth section's ends. 9. Tighten the Capsule Disc Mount with an Allen key. 10. Insert two empty capsules into the slots inside the front teeth section's ends. 10.1 Note: Ensure that the capsule bodies are in line with the front teeth.
  • Page 33 11. Plug in the machine. 12. Press the down arrow on the Capsule Sewer's VFD to lower the speed. 12.1 Note: Lowering it to 10 is the appropriate speed. 13. Press the Capsule Sewing button and run the machine for one rotation to ensure the front and back teeth sections are in alignment.
  • Page 34 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, ALWAYS unplug the SACF 25 ® from the electrical outlet when adjusting the Air Pressure.

  • Page 35: Maintenance

    Lubrication Regularly greasing your machine is vital to prolonging its operational life. Parts that are not greased properly can make the machine seize up and cause major problems later. LFA recommends maintaining a lubrication schedule for your SACF 25 ®...
  • Page 36 2. Trace the washers on the mounting block with a permanent marker. 2.1 Note: This is to mark the correct position of the bolts and washers in the mounting block for reinsertion. 3. Remove the mounting block from the machine by loosening its bolts with an Allen key. 4.
  • Page 37 5. Apply grease to each of the bearings inside the Capsule Sewing Mechanism. 6. Remove the two door panels located in the back of the machine. 7. Apply oil to the Gearbox above the machine's electrics.
  • Page 38 Lubrication Schedule LFA recommends the following SACF 25 parts to be lubricated according to the following ® frequency: Part Location Image Frequency Type of Lubricant Mounted above Visually inspect through the Motor in the the eye glass and apply 460 Grade Worm Gear...

  • Page 39: Dismantling For Repair And Replacement

    ® https://www.lfacapsulefillers.com/products/machine-spare-parts/sacf-range-spare-parts Warranty To access LFA's warranty policy, go to https://www.lfacapsulefillers.com/warranty If your part is eligible for warranty, have your part’s serial number on hand and please contact LFA: Phone Phone +44 01869 250234 +1 (682) 312-0034 Email Email support.uk@lfamachines.com...

  • Page 40: Wear Parts And Causes Of Damage

    Wear Parts and Causes of Damage Wear Part Cause of Damage Capsule Discs The Capsule Discs on the SACF 25 ® hold the capsule bodies and caps while they are being filled. It would be a good idea to have spare a Capsule Disc to increase production capacities and in the event of a damaged occuring during cleaning or mishandling.
  • Page 41 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, ALWAYS unplug the SACF 25 ® from the electrical outlet when replacing parts.
  • Page 42 3. Remove the two bolts on the Capsule Hopper with an Allen key. 3.1 Note: Ensure to support the weight of the Capsule Hopper when removing the bolts. 4. Remove the Capsule Hopper from the machine. 4.1 Note: Be careful when removing the Capsule Hopper. The Capsule Magazine is fragile, so ensure not to knock it with the Capsule Hopper.
  • Page 43 5. Remove the Capsule Discs from the machine. 6. Remove the front two bolts of the sewing section with an Allen key. 6.1 Note: Ensure to keep hold of the Capsule Magazine to prevent it from falling. 7. Remove the bolts from the front teeth section of the Capsule Sewer with an Allen key. 8.
  • Page 44 9. Remove the bolts in the back teeth section of the Capsule Sewer with an Allen key. 10. Pull out the back teeth section of the Capsule Sewer. 11. Remove the nut and washer from the Capsule Ejection Disc with a 24 mm wrench.
  • Page 45 12. Pull out the Capsule Ejection Disc from the sealing section. Replace the Tooling 13. Insert the new Capsule Ejection Disc into the sealing section. 13.1 Note: Ensure that the new Capsule Ejection Disc is secure on the thread. 14. Insert the washer and nut back on the thread and tighten with a 24 mm wrench.
  • Page 46 15. Insert the new back teeth section and secure the two bolts fingertight. 15.1 Note: The new back teeth section should be loose and able to move. 16. Insert the new front teeth section and secure the two bolts fingertight. 16.1 Note: The new front teeth section should be loose and able to move.
  • Page 47 17. Insert the new Capsule Discs in front of the sewing section. 18. Insert the Alignment Tools inside the new Capsule Discs and front teeth section. 19. Loosen the Capsule Disc Mount with an Allen key. 20. Adjust the Capsule Disc Mount and the new Capsule Discs. 20.1 Note: Ensure that the Alignment Tools rotate freely inside the front teeth section's ends and the Capsule Discs.
  • Page 48 24. Insert two empty capsules into the slots inside the front teeth section's ends. 24.1 Note: Ensure that the capsule bodies are in line with the front teeth. 25. Plug in the machine. 26. Press the down arrow on the Capsule Sewer's VFD to lower the speed. 26.1 Note: Lowering it to 10 is the appropriate speed.
  • Page 49 28. Tighten the back teeth section's bolts with an Allen key. 29. Run the machine for one more rotation to ensure that the Capsule Sewer is operating correctly. 30. Run the Capsule Sewer until it is at its highest position. 31.
  • Page 50 35. Press the Capsule Sewing button and run the machine for one rotation to ensure that the capsules are inserted into the Capsule Discs correctly. 36. Reinsert the Capsule Hopper on top of the new Capsule Magazine. 36.1 Note: Ensure not to knock the new Capsule Magazine. 37.
  • Page 51 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, ALWAYS unplug the SACF 25 ® from the electrical outlet when replacing parts.
  • Page 52 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, ALWAYS unplug the SACF 25 ® from the electrical outlet when replacing parts.
  • Page 53 2. Reach inside the Powder Hopper's mouth and grab onto the Auger. 3. Pull up the top of the Powder Hopper and the Auger from the machine.
  • Page 54 4. Remove the lower bolts on the Powder Hopper with a 13 mm wrench. 5. Remove the bottom of the Powder Hopper. 6. Remove the Auger teflon wear part with a crosshead screwdriver.
  • Page 55 Replace the Auger Teflon Wear Part 7. Secure the new Auger teflon wear part with a crosshead screwdriver. 8. Resecure the bottom bolts of the Powder Hopper with a 13 mm wrench. 9. Resecure the top bolts of the Powder Hopper with a 13 mm wrench.
  • Page 56 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, ALWAYS unplug the SACF 25 ® from the electrical outlet when replacing parts.
  • Page 57 3. Remove the two bolts on the Capsule Hopper with an Allen key. 3.1 Note: Ensure to support the weight of the Capsule Hopper when removing the bolts. 4. Remove the Capsule Hopper from the machine. 4.1 Note: Be careful when removing the Capsule Hopper. The Capsule Magazine is fragile, so ensure not to knock it with the Capsule Hopper.
  • Page 58 5. Remove the front two bolts of the sewing section with an Allen key. 5.1 Note: Ensure to keep hold of the Capsule Magazine to prevent it from falling. 6. Remove the screws on the back of the Capsule Magazine with a crosshead screwdriver.
  • Page 59 7. Remove the bolts that hold the Capsule Magazine's teeth with an Allen key. 8. Set aside the Capsule Magazine's teeth. 8.1 Note: Be careful not to lose the spring.
  • Page 60 9. Remove the Capsule Holding Pins' screws with a crosshead screwdriver. 10. Remove the Capsule Holding Pins from the Capsule Magazine. Replace the Capsule Holding Pins 11. Insert one of the new Capsule Holding Pins into the Capsule Magazine. 11.1 Note: Ensure that the new Capsule Holding Pin is straight and inserted at the correct length.
  • Page 61 16. Plug in the machine. 17. Press the down arrow on the Capsule Sewer's VFD to lower the speed. 17.1 Note: Lowering it to 10 is the appropriate speed. WARNING: To prevent any potential personal injury, keep hands and fingers away from the Capsule Sewer during operation.
  • Page 62 18. Run the Capsule Sewer until it is at its highest position. 19. Insert the Capsule Magazine onto the Capsule Sewing Mechanism's pins. 20. Tighten the Capsule Magazine's two bolts fingertight. 21. Ensure that all the teeth in the Capsule Magazine and the rest of Capsule Sewing Mechanism are aligned and fully tighten the two bolts with an Allen key.
  • Page 63 23. Press the Capsule Sewing button and run the machine for one rotation to ensure that the capsules are inserted into the Capsule Discs correctly. 24. Reinsert the Capsule Hopper on top of the Capsule Magazine. 24.1 Note: Ensure not to knock the Capsule Magazine. 25.
  • Page 64 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, ALWAYS unplug the SACF 25 ® from the electrical outlet when replacing parts.
  • Page 65 2. Carefully remove the Vacuum Pump's cover and set aside. 3. Lift up the Filter Bag off of the Vacuum Pump. Replace the Vacuum Pump Filter Bag 4. Insert the new Filter Bag over the bolts and into the Vacuum Pump. 5.

  • Page 66: Troubleshooting

    Troubleshooting Sometimes unavoidable issues will occur while operating the SACF 25 ® . Fortunately, there are several methods to remedy these issues. Common Issues Symptom Possible Cause Possible Solution Adjust the vacuum pressure to Capsule caps fly from machine The vacuum pressure is too high.

  • Page 67: Common Issues Continued

    Symptom Possible Cause Possible Solution Remove the Capsule Magazine and run the cleaning brush included with The Capsule Magazine is clogged. the SACF 25 ® Toolkit through the Capsules are not being fed through tracks. the Capsule Magazine's tracks Adjust the Capsule Magazine so that...

  • Page 68: Common Issues Continued

    Replace the damaged capsules. interface (sealing area). Improperly closed capsules Use larger capsules. The capsules are being overfilled. Use less powder. Use a capsule polisher after filling capsules. Order one from LFA at Dusty capsules Capsules are not being polished. https://www.lfacapsulefillers.com/cp- 7000-capsule-polisher...

  • Page 69: Jamming The Sacf

    • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, ALWAYS unplug the SACF 25 ® before de-jamming it.
  • Page 70 Method 2: Clean Excess Powder Buildup 1. Remove the Capsule Hopper, the Powder Hopper, the Capsule Magazine and teeth, the Capsule Discs, the Capsule Ejection Disc, and the Auger. 1.1 Note: Please refer to the remove and replace Tooling instructions on page 41 for further assistance and the remove and replace Auger Teflon Wear Part instructions on page 52 for further assistance.

  • Page 71: Cleaning

    • Potable water • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, ALWAYS unplug the SACF 25 ® from the electrical outlet when removing and replacing parts.
  • Page 72 9. Spray the SACF 25 base with the cleaner, particularly in the location of the Tooling and Excess ® Powder Collector. 10. Rinse the cleaner off with potable water. 11. Sanitize the the SACF 25 base with a clean cloth. ®...

  • Page 74: Storing The Sacf

    After its thorough cleaning, the SACF 25 ® needs to be stored in the proper conditions. It is important to store it in an environment in which the machine is safe from rusting. The SACF 25 ® ’s high traction areas and the Tooling need to be lubricated separately before you store them.
  • Page 75 3. Remove the mounting block from the machine by loosening its bolts with an Allen key. 4. Remove each of the four panels that enclose the Capsule Sewing Mechanism with an Allen key. 5. Apply grease to each of the bearings inside the Capsule Sewing Mechanism.
  • Page 76 6. Remove the two door panels located in the back of the machine. 7. Apply oil to the Gearbox above the machine's electrics. Environmental Conditions It is important that the environment in which you store the SACF 25 ® has the appropriate temperature and relative humidity levels.

  • Page 77: Appendix

    Appendix Glossary Term Definition Any substance or mixture of substances used API/Active Pharmaceutical Ingredient that is an active ingredient in the drug product. Disc that contains pins to seal and eject Capsule Ejection Disc capsules when the Capsule Discs are pushed against it.

  • Page 78: Description Of Sacf 25 ® Parts

    Description of SACF 25 Parts ® Filter Bag for Capsule Filler Vacuum Pump The Filter Bag for the Capsule Filler Vacuum Pump catches dust and debris that come from the machine's operation. Order at https://www. lfacapsulefillers.com/filer-bag-capsule-filler- Tooling vacuum-pump The Tooling consists of the Capsule Discs, the Capsule Ejection Disc, and the Capsule Magazine.
  • Page 79 Teflon Wear Part on Vacuum Section This wear part sits between the vacuum section and on the main body of the machine and the Capsule Discs when the capsules are being sewn and maintains a seal between the disc and the vacuum. Order at https://www.

  • Page 80: Food Grade Point Of Contact Parts

    Food Grade Point of Contact Parts Contact Part Material Capsule Discs LY12 aluminum alloy Capsule Ejection Disc LY12 aluminum alloy and SUS304 Powder Hopper SUS304 Capsule Hopper SUS304 Alignment Tools SUS304 Technical Specifications Maximum output up to 25,000/hr (#2 size) Compatible capsule sizes #00L, #00, #0, #1, #2, #3, #4, #5 Filling precision...

  • Page 81: Maintenance Checklist

    Maintenance Checklist Before Operation Visually inspect the semi-automatic capsule filler and the parts. Ensure all nuts and bolts are tight. Visually inspect grease points and regrease where necessary. Run the machine at a slow speed to ensure that everything is operating correctly. Visually inspect electrical wires for any damage.

  • Page 82: Diagrams

    Diagrams SACF 25 Tooling Dimensions ®...
  • Page 83 SACF 25 Air Drawing ®...
  • Page 84 SACF 25 Wiring Diagram ®...
  • Page 85 SACF 25 Floor Plan ®...

  • Page 86: Resources

    In order to aid you in your capsule production, give you a visual aid that will hopefully support LFA Machines maintains a website that offers a you in your capsule production efforts. To watch breadth of useful information about the SACF our videos, visit https://www.youtube.com/...
  • Page 87 LFA MACHINES Copyright © 2022 by LFA Machines www.lfamachines.com Germany Taiwan United Kingdom United States Business Parc Am Unit 4B 6601 Will Rogers Blvd 7F.-5, No. 2, Sec. 2 Trippelsberg 92 Murdock Road Fort Worth Taiwan Blvd., West Dist., Düsseldorf...

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