Tablet Counting & Filling Machines
High-precision, cGMP compliant automatic electronic multi-channel tablet, pill, hard capsule, and softgel counting and bottling packaging systems with 99.99% counting accuracy, infrared optical matrix sensors, dust compensation, and automated reject mechanisms.
Description
Automatic tablet counting and filling machines are high-speed solid dosage packaging systems engineered to count, verify, and bottle tablets, caplets, hard gelatin/HPMC capsules, softgels, dragees, and pills with exceptional accuracy and zero product damage. Backed by over 40 years of precision packaging machinery engineering in India, HMEC manufactures a comprehensive portfolio of electronic multi-channel tablet counters designed in accordance with rigorous cGMP and FDA sanitary standards.
Our tablet counting systems utilize a state-of-the-art 3-tier electromagnetic vibratory feed tray system that smoothly spreads bulk product into single-layer aligned tracks. High-frequency infrared optical counting sensors or high-resolution camera vision arrays detect each piece across 8, 12, 16, 24, or 32 channels simultaneously. Featuring dynamic auto-dust accumulation compensation, servo-actuated anti-jam diving funnels, pneumatic container gating, and integrated rejection systems for over/under fills, HMEC counting lines deliver speeds up to 180+ bottles per minute while eliminating human error and product contamination.
Type of Machine
On basis of heads & tracks
- ✅ Single Head (8 / 12 Tracks - 25-50 BPM)
- ✅ Double Head (16 / 24 Tracks - 50-100 BPM)
- ✅ Triple Head (24 / 36 Tracks - 90-140 BPM)
- ✅ Four Head / Quad Head (32 / 48 Tracks - 120-180+ BPM)
- ✅ Semi-Automatic Rotary / Disc Tablet Counter
Solid dosage product compatibility
- ✅ Coated / Sugar-Coated Tablets & Caplets
- ✅ Uncoated Compressed & Micro-Tablets
- ✅ Hard Gelatin & HPMC Capsules (#000 to #5)
- ✅ Softgel Capsules (Round, Oval, Oblong)
- ✅ Effervescent Tablets & Chewable Wafers
- ✅ Ayurvedic Pills, Lozenges & Gummy Candies
Sensing & counting technology
- ✅ Multi-Beam Infrared Optical Matrix Sensors
- ✅ High-Speed CCD / CMOS Camera Vision Verification
- ✅ Automatic Dust Accumulation Compensation
- ✅ Inline Checkweigher with Over/Under Count Detection
- ✅ Broken / Chipped Tablet & Debris Separation
Integrated bottling line equipment
- ✅ Rotary Bottle Unscrambler & Infeed Turn Table
- ✅ Inverted Air Jet Vacuum Bottle Cleaner
- ✅ Automatic Silica Gel / Desiccant Inserter
- ✅ Automatic Rayon / Cotton Coil Inserter
- ✅ Automatic ROPP / Screw / CRC Capping Machine
- ✅ Induction Cap Sealing & Sticker Labeling Line
5-Stage High-Accuracy Counting & Bottling Process
HMEC automatic electronic tablet counting lines execute a synchronized multi-stage feeding, scanning, and container filling process to guarantee 99.99% counting accuracy and zero bottle blockage:
Bulk Hopper & 3-Tier Feeding
Tablets flow from a sanitary SS 316 hopper onto three cascaded electromagnetic vibratory plates, separating clusters into uniform single-file streams across parallel channels.
Dust Vacuum & Chip Removal
Integrated vacuum suction manifolds extract airborne dust and fine powder while specialized mesh tracks drop broken fragments before tablets reach optical scanning heads.
High-Speed Optical Scanning
High-frequency infrared matrix sensors count each tablet in mid-flight with sub-millisecond response and auto-adjust for dust buildup without false triggers.
Servo Bottle Indexing & Funnel Dosing
Pneumatic gating pins position empty bottles beneath servo-actuated diving funnels that descend into bottle mouths to prevent tablet bridging and spillage during rapid filling.
"No Bottle - No Fill" & Rejection
Optical interlocks halt counting if a bottle is missing. Any container with count discrepancy is dynamically diverted into a locked reject bin via an automated pneumatic pusher.
Salient Features
- cGMP compliant heavy-duty AISI 304 frame structure with all product contact components in polished AISI 316 / 316L stainless steel
- Advanced 3-tier stepped electromagnetic vibratory trays with independent multi-frequency vibration control for smooth, gentle product progression
- High-frequency infrared sensor matrix providing 99.99% counting accuracy across transparent, translucent, and opaque capsules or tablets
- Dynamic auto-dust accumulation compensation algorithm ensuring reliable operation even with heavily dusted uncoated tablets
- Smart optical interlock system with "No Bottle – No Count – No Fill" and container fallen/jam sensing to avoid spillage and product wastage
- Servo-controlled diving delivery nozzles and anti-jam flap gates engineered for zero tablet crushing, pinching, or mouth bridging
- Tool-free rapid changeover system accommodating various bottle diameters, bottle heights, and solid dosage shapes within 15-20 minutes
- Integrated vacuum extraction ports connected to internal suction manifolds to continuously collect loose dust during counting cycles
- Siemens / Allen-Bradley / Delta PLC with intuitive 7" to 10" Color Touchscreen HMI featuring 100+ product recipe memory and multi-tier security
- Fully compliant with 21 CFR Part 11 electronic records, batch reporting, audit trails, and turnkey integration into downstream bottling lines
Technical Specifications
| Production Output Speed | Up to 25 to 180+ Bottles Per Minute (BPM) (Depending on model, channel count & count per bottle) |
|---|---|
| Counting Channels / Tracks | 8, 12, 16, 24, 32 or 48 Channels (Configurable in Single, Double, Triple, or Quad Head setups) |
| Counting Range | 1 to 9,999 pieces per bottle (Freely programmable via PLC touchscreen HMI) |
| Counting Accuracy | ≥ 99.99% with dynamic over/under count verification |
| Tablet / Capsule Compatibility | Round/oval tablets (Ø 3 mm - Ø 25 mm), Caplets, Hard Capsules (#000 to #5), Softgels (all shapes) |
| Container Size Range | Bottle Diameter: Ø 20 mm to Ø 100 mm | Bottle Height: 40 mm to 220 mm (Customizable for jars) |
| Container Compatibility | Plastic (HDPE, PET, PP), Glass Bottles, Metal Cans, Wide-Mouth Jars, and Rigid Tubs |
| Material of Construction | AISI 316 / 316L Stainless Steel & FDA-approved polymers for contact parts; AISI 304 for exterior casing |
| Dust Extraction | Built-in dust collection ports (Ø 38 mm / Ø 50 mm) for external industrial dust extractor connection |
| Rejection Mechanism | Automatic pneumatic diverter / high-speed air blast cylinder into a locked rejection bin |
| Control Architecture | PLC with Color Touchscreen HMI (Siemens / Delta / Allen-Bradley) with Recipe Management & Alarms |
| Air Requirement | 5 to 6 Bar Clean, Dry, Oil-Free Compressed Air (120 - 250 L/min) |
| Power Requirement | 415V / 3 Phase / 50 Hz (1.5 kW to 4.5 kW) (Customizable for 220V/480V 60Hz global supplies) |
Technology & Model Comparison Matrix
Compare our tablet and capsule counting machinery models to select the ideal configuration for your facility's production scale and automation requirements:
| Feature / Parameter | Semi-Automatic Counter | Single Head (8/12 Track) | Double Head (16/24 Track) | High-Speed Multi-Head Line |
|---|---|---|---|---|
| Operating Principle | Rotary disc / dual-hopper manual load | Linear 3-tier vibratory multi-channel | Dual 3-tier vibratory synchronized heads | Triple / Quad multi-track continuous line |
| Production Output | 10 to 25 BPM | 30 to 50 BPM | 60 to 100 BPM | 120 to 180+ BPM |
| Counting Channels | 1 - 2 Chutes | 8 to 12 Channels | 16 to 24 Channels | 24 to 48 Channels |
| Counting Accuracy | 99.5% | 99.99% | 99.99% | 99.99% + Vision / Weight Check |
| Bottle Handling | Manual bottle placement | Automatic inline conveyor gating | Dual-track continuous gating system | Continuous servo synchronized indexing |
| Dust Compensation | Manual cleaning | Automatic sensor algorithm | Automatic sensor algorithm + vacuum | Multi-point vacuum + real-time calibration |
| Rejection System | Manual inspection | Pneumatic reject arm / gate | High-speed pneumatic diverter | Multi-tier rejection with verification bin |
| Ideal Application | R&D labs, pilot batches, hospital pharmacy | Small to medium pharma packaging | High-throughput pharmaceutical & nutra lines | Ultra-high-volume contract packagers |
Complete Solid Dosage Bottling Packaging Line Integration
HMEC provides end-to-end automated turnkey packaging lines for solid dosage pharmaceuticals and nutraceuticals, seamlessly integrating every process from empty container preparation to final carton packing:
Videos of Tablet Counting Machine
Automatic Electronic Tablet Counting & Filling Machine
High-Speed Multi-Head Tablet & Capsule Packaging Line
Range of Tablet Counting and Filling Machines
Automatic Electronic Tablet Counting Machine
High-speed multi-channel electronic counting and filling machine with infrared scanning, auto-dust compensation, and pneumatic bottle gating up to 100+ BPM.
Single Head Tablet Counting Machine
8 or 12-channel single head counter engineered for small to medium production batches with 99.99% accuracy and speeds up to 50 BPM.
Double Head Tablet Counting Machine
Dual-head 16 or 24-channel counting and filling system providing high throughput up to 100 BPM with twin filling nozzles and redundant optical tracks.
Semi-Automatic Tablet Counting Machine
Compact table-top rotary disc counting system designed for R&D laboratories, clinical trial batches, and small pharmaceutical production runs.
Cotton Inserter Machine
Continuous rotary / linear machine engineered to accurately cut, fold, and insert continuous cotton coil or rayon into bottles to protect tablets during transit.
Silica Gel / Desiccant Inserter
High-speed automated inserter for silica gel sachets or plastic canisters into bottles to ensure humidity protection for moisture-sensitive solid dosages.