Tianfu series mid-to-large scale production unit, perfectly sized for standard pharmaceutical or nutraceutical manufacturing. A 450L capacity typically represents a "sweet spot" — it's large enough to support a full 8-hour production shift on a standard softgel line without needing constant refills, yet compact enough to fit in most clean rooms.
Here is the technical breakdown of a 450L Batching and Gelation System.
🏭 System Overview: The "Two-Stage" Process
For a volume of 450L, the system is rarely a single tank. It is almost always a two-vessel configuration to ensure efficiency:
Why two tanks? You cannot mix and feed the machine simultaneously with the same tank. You need to prepare the next batch while the machine is running on the current batch.
⚙️ Key Components & Specifications
- Capacity: 450 Liters (Working volume approx. 350L - 400L to allow head space).
- High-Speed Homogenizer: A top-mounted high-shear mixer (3000 rpm) is crucial to disperse the gelatin powder into the water/glycerin mix without forming lumps ("fish eyes").
- Slow-Speed Stirrer: An anchor or paddle stirrer (variable speed) ensures the thick gel mass is moved around the walls and heated evenly.
- Vacuum System: A vacuum pump (-0.09 MPa) removes air bubbles introduced during mixing. This is critical for capsule clarity.
- Heating: Double-jacketed (dimple jacket or full jacket) using hot water or steam to melt the gelatin (typically 60°C - 80°C).
- Capacity: 450 Liters (or split into two smaller tanks).
- Temperature Control: Precision heating jacket to maintain the gel at exactly 60°C ± 1°C. If it gets too cold, it gels; too hot, it degrades.
- De-aeration: Maintains a vacuum to keep the gel bubble-free during the "aging" period (resting time).
- Transfer Pump: A sanitary lobe pump or gear pump transfers the gel from the Mixing Tank to the Storage Tank, and finally to the Softgel Machine's Melting Tank.
- Contact Parts: High-grade SUS316L Stainless Steel.
- Surface Finish: Internal polish to Ra ≤ 0.4μm (Mirror finish). This prevents bacteria growth and makes cleaning easier.
- External Finish: Satin finish or polished for aesthetics.
📝 Typical Process Flow (Step-by-Step)
📊 Technical Data Sheet (Estimates)
Parameter Specification
Total Capacity 450 Liters (Gross) / ~380 Liters (Working)
Design Pressure Jacket: 6 Bar / Vessel: -1 to 0.5 Bar
Mixing Power 5.5 kW - 7.5 kW (High Shear)
Stirring Power 2.2 kW - 4.0 kW (Anchor)
Heating Medium Hot Water (60°C - 90°C) or Steam
Cooling Medium Chilled Water (for temperature drop if needed)
Control System PLC with Touch Screen
Dimensions Approx. 1.2m (W) x 1.2m (D) x 2.5m (H)
💡 Why 450L?
A 450L system is the industry standard for medium-to-high volume production.
- Yield: One 450L batch of gel mass can produce approximately 300,000 to 500,000 softgel capsules (depending on capsule size, e.g., 1000mg vs 500mg).
- Efficiency: It matches the consumption rate of standard encapsulation machines , ensuring the machine never stops waiting for gel.
