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GKF 2500 | GKF 3000

The compact capsule filling machine for high performance

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Ergonomical and secure handling

With the focus on ergonomics and cleanability, our engineers

have developed a machine that minimizes change-over and

cleaning times and therefore maximizes productivity. The

cGMP-compliant production cabin ensures easy accessibility

and user-friendly operation and cleaning. Likewise, machine

sub-assemblies are quick and easy to exchange – during for-

mat changeovers, for example.

Machine control is via the touch-screen HMI, and is especially

user-friendly. The control of the machine and measurement

data collection are handled via an industrial PC. All producti-

on data is also saved and managed on the industrial PC. The

Windows-based software complies with the data security

guidelines of 21 CFR part 11.

Quick and easy operation

The machine table-top is seamlessly machined as one piece.

This allows for large-radius contours without undercuts, accor-

ding to proper GMP design. Furthermore, only FDA-approved

materials are used. The maintenance-free main drive makes

the machine quiet in operation, reduces wear, and extends the

machine‘s service life..

Flexibility and economy in operationfor capsule fi llingWhichever products you would like to fi ll – powders, pellets, tablets, liquids, micro-dosing or

combinations, the GKF 2500 offers a great solution in the high-speed production range.

The design of this capsule fi ller allows for quick and complete cleaning, as well as effi cient

changeovers. The GKF 2500 fulfi lls all modern cGMP requirements in the process, setting new stan-

dards in pharmaceutical security.

� Highly accurate dosing

� Simple operation

� cGMP-compliant design

� Flexible dosing possibilities

� Low-maintenance operation

� Data security

� Reliability

� Optimal accessibility

ADVANTAGES AT A GLANCE

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GKF 2500 The GKF 2500 is a versatile and flexible machine that pro-

vides a great range of fill options for varying product types.

Even complex products with varying fill parameters are easy

to process. Thanks to the modular design of this capsule

filler, the machine can be changed over in the minimum

amount of time.

GKF 2500 ASB 100 %The GKF 2500 ASB 100% is equipped with an integrated

checkweigher. Every capsule produced on the machine is

individually and precisely weighed. Only capsules with a

weight within the pre-set tolerances are accepted. Over-

and underweight capsules are rejected.

GKF 3000 The GKF 3000 is based on the successful GKF 2500 and sets

a new benchmark in the pharmaceutical industry with its out-

put of 175,000 capsules per hour. This machine is reliable,

low-maintenance, and provides production security.

As the fastest tamping pin principle machine on the market,

the GKF 3000 offers precise dosing with minimal product

loss. Powder or pellet products are gently filled and even pro-

ducts with varying fill parameters can be optimally filled via

height-adjustable dosing disks. A special seal separates the

production and drive cabin, thereby protecting the product

from foreign contaminants.

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Capsule orientation and separation

Capsule orientation and separation

Capsule cap scanner (ASB function)

Free for an optional pellet or tablet station

Dosing station for powder/pellets via fi xed or height-adjustable dosing disk, liquid fi lling station or micro-dosing station

Free for optional pellet or tablet station

Faulty-capsule rejection

Free for optional pellet or tablet station *

Capsule closing with capsule body scanner (ASB function)

Individual capsule ejection with ASB function

Individual capsule ejection with ASB function

Segment cleaning with compressed air (ASB function)

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Description of functionsand dosing options

No ASB function available on the GKF 3000* Optional pellet station on the GKF 3000

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Powder/pelletsDosing station with patented slide-gatetechnology for the filling of powder and pellets. For powders, the proven tam-ping pin method is used; with pellets, the exact dosing is achieved using a fixed or height-adjustable dosing disk.

Micro dosingHighly accurate, agglomeration-freemicro dosing of powders using a micro dosing wheel (e.g. for inhalation) at maximum output.

PelletsThe pellet station is a gentle, precise, and

compact option for dosing pellets with

different characteristics.

(Micro-) TabletsThe tablet station is a gentle and precise solution for dosing of single and multiple tablets into capsules.

LiquidsThe liquid station with its integrated drip retraction feature enables the precise volumetric dosing of everything from hydrophilic to thixotropic liquids. It also has the ability to heat or cool liquids during the filling process.

CombinationsA wide array of product combinations

are possible on the GKF series, thanks

to its modular assembly.

Customized solutionThanks to the open platform, the GKF series is a filling machine that offers the flexibiliy to meet any filling solution re-quirements of the future.

Equipped with the respective fi lling station, the GKF series achieves precise fi lling results for every-

thing from free-fl owing to cohesive powders, as well as for products of a liquid or pasty nature.

We will be happy to develop a customized solution for your products and product combinations –

regardless of their physical properties.

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Reliable operation via automatic troubleshooting Automatic troubleshooting during operation enables auto-

mated, continuous production and reduces downtimes, even

without the intervention of an operator.

The calibration strip in the empty capsule sorting magazine

ensures that deformed or damaged empty capsules are

removed even before they reach the filling station.

The mechanical capsule cap scanner determines if there are

blockages in the empty capsule infeed. A repeated missing

capsule in a particular segment bore is detected by the

consecutive fault function. Deformed capsules in the capsule

magazine are blown out via individual compressed air lines

and rerouted to a separate deformed capsule container.

The capsule body scanner detects incomplete capsules during

capsule closing – stopping incomplete capsule portions from

making it into the good capsule production container.

Capsules that have been determined to be faulty are individ-

ually rejected at the 18 capsule ejection flaps. The segment

cleaning station uses compressed air nozzles to loosen sticky

products and capsule fragments from the segment bores and

reliably vacuum them away. This station ensures the cleaning

of all the segments for the next filling cycle.

Optimal productivityvia quality control

ASB funktion

Mechanical capsule cap scanner Single capsule ejection of faulty capsules

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GKF 2500 ASB 100% with online weight control Beyond the advantages of ASB, the integrated weighing sys-

tem offers you a secure and documented production process.

The highly accurate weight-control feature automatically con-

trols fill weights with its pneumatic adjustment of the tamp-

ing pin pressure. This ensures that the desired fill weight is

maintained within the specified tolerance range for the entire

production process.

The electrical height adjustment of the dosing disc allows

for automatic regulation of the filling volume. This ensures a

dosing weight within the required tolerance limits through-

out the entire production process.

The analysis software calculates an average fill weight from

the checkweigher results and compares this average to the

theoretical fill weight. If a capsule is outside the tolerance

range, it is automatically rejected. The incident will then be

documented in the production report.

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� Out-of-tolerance capsules are automatically rejected

� Reduction of machine downtimes

� Lights-out operation

� The capsule fi lling machine can be operated with or without the 100% checkweigher

� The checkweigher can be operated with or without the capsule fi ller

ADVANTAGES AT A GLANCE

The GKF 2500 series guarantees optimal productivity and pharmaceutical security in capsule fi lling

with its automatic troubleshooting feature (ASB) for the GKF 2500 ASB and GKF 2500 ASB 100%

versions.

Automatic, electric height-adjustable dosing disc

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Capsule hopper

Insertion pusher

Magazine

Calibration bar

Size plate

Separating fl aps

Transport fi nger

Weighing cell

Transport wheel

Discharge fl ap

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Description of functions 100% check weighing

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Accurate weighing methodThe Bosch patented “hanging weigh cell” principle safely

weighs all capsules while avoiding dust or residue build up

within the weighing cell. In addition, the weigh cell design eli-

minates electrical interferences such as electrostatic fields.

Dependable production documentationData for the entire production run is stored and digitally

evaluated by the user-friendly operating system. All of the data

available on the system can be saved on the integrated DVD

Burner or transferred to an external system via the USB port.

Size changeover in < 1 minThe ergonomic design, which sucessfully meets cGMP requi-

rements, permits a size changeover in less than one minute.

All change parts can be quickly disassembled without tools,

allowing for rapid cleaning with no residues.

Easy, fast cleaningDue to the hermetic separation of the production and drive sec-

tion (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.

KKE 2500, the precise checkweighing unit for the GKF 2500

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Machine cycles � Max. 140 cycles/min.

Electrical connection � 380–480 V, 50/60 Hz 3 pH/PE

� Special voltages

� 16 kVA total

Maximum amperage � 16A

Vacuum pump electrical connection � 1.85 kW, 50 Hz, 2,2 kW, 60 Hz

Vacuum requirement � 50 m³/h at −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

Infeeds � Powder infeed – Triclamp DN 150,

DIN 32676

� Pellet/tablet infeed – Triclamp

DN 100, DIN 32676

� Empty capsule infeed – Triclamp

DN 100, DIN 32676

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

� Dosing station with fi xed or

height-adjustable dosing disc

and product container

� Product container with minimum

and maximum level control¹

� Adjusting device for reproducible

height-adjustment of the dosing disc

� Capsule closing station

with concave closing pins

� Cleaning station with compressed

air nozzles and vacuum suction¹

Formats � Capsule format set for all standard

capsule sizes, 00 to 5, DB

Options � Height-adjustable dosing disc

Filling options � Powder fi lling station

� Pellet fi lling station

� Liquid fi lling station²

� Tablet fi lling station

for various tablet forms²

� Micro dosing station²

Accessories � Vacuum pump for capsule separation

� Dust collector

� Automatic powder feeding

� Empty capsule feeder

� Capsule polisher

� Metal detector

� Distribution system

¹ optional on GKF 2500 and GKF 3000 ² not on the GKF 3000

Technical data

2500 2500 ASB 2500 ASB 100 % 3000GKF

Output (max. capsules/h) 150,000 150,000 150,000 175,000

Segment bores 18 18 18 21

Compressed air consumption (m3/h at 5 bar) 2 2 20 2

Dust-collector electrical connection

200 | 220 | 380 | 400 V50 Hz, 2 x 2.55 kW

220 | 230 | 380 | 400 | 460 | 480 V60 Hz, 2 x 2.55 kW

Dust-collector air fl ow volume 820 m³/min, open suction

Weight (kg) ca. 1,700 ca. 2,000 ca. 3,300 ca. 1,700

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Layout and top view23

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1389

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3061

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GKF 2500 / GKF 2500 ASB / GKF 3000

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1389

2466

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3061

2027

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GKF 2500 ASB 100 %

Customized after-sales support service solutions for the entire life cycle of your machines

By investing in a Bosch packaging machine, you gain access to

an extensive range of after-sales services.

We are always there for you: providing reliable services from a

single source, all over the world. It already begins during the

project phase with services such as process consulting, system

planning, or lab services. And it continues during operation:

from spare parts and field service offerings to stock optimiza-

tion, modernization, and preventive maintenance, all the way

to remote and data-based services and training. Whether it’s a

customized solution or a standard service – together with us

you achieve maximum output with minimum downtime and

optimize the profitability of your machines.

For more detailed information please visit our website:

http://www.boschpackaging.com/en/pa/services/after-sales-services/service.html

Robert Bosch Packaging Technology GmbHProduct Division Pharma Solid

Stuttgarter Straße 130

71332 Waiblingen

Germany

Phone +49 711 811 - 0

www.boschpackaging.compackaging-ph@bosch.com PA

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