AN INTEGRATED CAPSULE HANDLING SYSTEM WITH CONTACTLESS ELECTROMAGNETIC MANUFACTURING SYSTEM (CEMS)

Abstract

The present disclosure relates to capsule-filling manufacturing unit. The capsule-filling manufacturing unit includes a capsule handling system (100) and an electromagnetic mover system. The capsule handling system (100) includes a plurality of stations located in a non-electromagnetic area (110) and adapted to perform a plurality of operations. A cap plate handling station (120) is adapted to separate a cap plate (401) from a body plate (302) and store the cap plate (401). The electromagnetic mover system located outside the non-electromagnetic area (110) and having at least one magnetic mover (112), at least one electromagnetic area (108), and at least one handling mechanism. The non-electromagnetic area (110) is adapted to provide a bottom passage (128) to access the body plate (302) to perform the plurality of operations in at least one of the plurality of stations in the capsule handling system (100).

Specification

Description:FIELD OF THE INVENTION

The present disclosure generally relates to a capsule-filling manufacturing unit, and more particularly, a capsule handling system for handling capsules integrated with a Contactless Electromagnetic Manufacturing System (CEMS).

BACKGROUND

Modern capsule-filling manufacturing involves high speed production on rotary and linear indexing machines that has not evolved in decades. The process of capsule-filling manufacturing is carried out in a linear environment involving multiple production stations with differing cycle times, limited modularity, limited flexibility, prone to entire line stoppages, long and complex batch changeouts and with almost no integration with packaging. Traditional capsule-filling manufacturing makes use of a 'single drive' approach where each index in a production line is fixed and dependent upon the indexing of processes ahead and behind. This methodology of indexing does not allow for production steps to operate independent of one another. It may be locked "in-step" with the rest of the production activities, largely inflexible and unable to optimize individual processes or flex with changing production criteria.

The current state of the art in capsule-filling manufacturing units incorporate a series of independent activities. These activities are run continuously in series, using a variety of different operations such as capsule loading, capsule separation, capsule dosing, capsule recapping, and capsule ejection. The operations are usually carried out on large-scale, high volume equipment that is highly integrated between the various operations. Further, the operations are often carried in large physical spaces located proximately or distant from one another utilizing linear and/or circuitous, intermittent, or continuous processes that are incapable of modification or flexibility. Thus, the capsule-filling manufacturing needs to evolve to better leverage modern manufacturing technologies and trends that are capable of modular production, flexibility, rapid batch, and parts changeover, is better equipped to deal with quality issues, routing, and downstream integration.

Conventionally, in a capsule-filling manufacturing unit, traditional production lines such as a sequential manufacturing processes set out in engineering design are employed. The sequential manufacturing processes are highly inefficient when dealing with production involving many co-dependent activities with lengthier times, where conditioning or dwelling are required. The sequential manufacturing process limits production output by the slowest cycle/process time. The major limitations of the sequential manufacturing process are as follows. Firstly, the sequential production process is severely hampered by the impact of production breakdowns and product failure. Any stoppage on any part of the line generally stops all production activities. Secondly, the sequential production process has challenges integrating with separate in-feed and out-feed lines especially in cases where those lines operate in a differing speed. Thirdly, the sequential production process suffers from a major lack of modularity, making the addition of functional stations and secondary processing impossible as well as making product, and batch changeover challenging. Fourthly, lack of modularity also limits manufacturer's ability to speed up production by adding additional production stations. Fifthly, the sequential production process is unable to buffer production to better account for stoppages or slowed production processes and in many cases product needs to be stockpiled "off-line" in order to be able to be introduced into the line when complete.

The traditional manufacturing process and architecture in the capsule-filling manufacturing has not been through any major change, mainly due to the complexity and inaccuracy of alternative systems. However, in recent times there has been a major change in production architecture resulting in a Contactless Electromagnetic Manufacturing system (CEMS). The changes may be attributed to firstly, development in contactless movement equipment making use of electromagnetic technologies. Secondly, development of locational accuracy in electromagnetic systems. Thirdly, development in power and speed of systems to accurately move and control electromagnetic systems. Fourthly, development in power and speed of information systems in individual tracking, scheduling, stacking, production and control over multiple movers in an electromagnetic system.

Presently, the Contactless Electromagnetic Manufacturing systems (CEMS) making use of electromagnetic technologies promises a viable alternative to the sequential manufacturing process in the capsule-filling manufacturing unit. The CEMS allows for highly accurate and free movement of carrier plates holding product. The movement of the carrier plates or movers allows the product to dynamically move through the production process. Further, the CEMS provides for modular scaling of production by adding or removing production stations. The modularity allows user to increase stations with slow indexing times, thereby optimizing production cycle times and significant improvement in production output. Further, the CEMS provides for the ability to infeed and outfeed between production lines and sub production areas with smart and efficient scheduling. The CEMS further provides the ability to dynamically route product in the manufacturing process according to real time availability of production stations, maximizing production output and utilization. The CEMS further provides for the ability to stack products in manufacturing process dynamically within the production area, thereby ensuring quantities of buffer items which ensure that there is no production waiting times and maximum efficiency. Furthermore, the CEMS provides for the ability to stack products in progress in the event of stoppages, cleaning or maintenance without stopping upstream processes. Also, the CEMS provides for the ability to change out batches quickly by only replacing certain modular stations. Moreover, the CEMS enable to route products in manufacturing process, finished products, packaging and other manufacturing inputs along any route. Further, the CEMS may also allow for modified production processes allowing typically complex and integrated production processes to be broken down into smaller more discrete processes that no longer require consolidation.

The Contactless Electromagnetic Manufacturing Systems employ magnetic movers that that are levitated above a manufacturing plane. The movers are contactless and flexible able to achieve significant manufacturing efficiency through dynamic routing, stacking, and independent travel, thereby achieving substantial optimization of manufacturing processes as well as accommodating rework, blockages and other optimization strategies. However, CEMS in its current configuration have severe restrictions in its applicability in the capsule-filling manufacturing unit.

The major limitations in the existing Contactless Electromagnetic Manufacturing Systems for employing in the capsule-filling manufacturing unit are load bearing limitation, system inefficiency, contamination risk during production corrective action and capsule handling and tracking. The movers in the existing CEMS are only able to handle limited weights and product densities limiting its overall application in the capsule-filling manufacturing unit. The movers being complicated electromechanical equipment are very sensitive for load bearing capacities. Since in contactless electromagnetic systems, the movers are moved and lifted using electromagnetic forces, the load bearing capacities are severely limited. When a material is dosed into containers held by the movers or performing a similar non-contact activity, the CEMS in its present configuration may unable to cater for any significant level of vertical force to be placed on the movers. In an example, the movers in the existing CEMS may be only capable of supporting a maximum weight of between 4.2kg and 6 kg. If the weight of the product as well as any potential product support is taken into consideration, the CEMS may not be able to resist any level of vertical load on the mover.

Conventionally, in a capsule-filling manufacturing unit, each of a capsule body is separated from a capsule cap and the capsule body may be proceeded for dosing operation. Following separation of each of the capsule bodies, the capsule caps need to be removed from a separation station by a pick and place component or robot. The capsule body carried by a body plate proceeds to one of capsule dosing station where value adding steps such as dosing materials into the capsule bodies, tamping and inserting membranes into the capsule body is carried out. Following the capsule dosing operation, each of the capsule body is reunited with the respective capsule cap through a telescoping action resulting in a complete capsule that is ejected at the end of the process. In this conventional capsule dosing operation, a cap plate has to be retained on the Contactless Electromagnetic Manufacturing Plane prior to recapping, although the cap plate has no production activity carried out upon it. That is, the CEMS may need to be expanded to accommodate the caps plates adding routing complexity, increased processing power for the electromagnetic software system and other related costs. Given the very high capital costs of deploying Contactless Electromagnetic Manufacturing systems this is an inefficient and less productive method of capsule dosing operation.

The manufacturing operation of dosing the capsule with a dosing material needs to be perfectly aligned with the CEMS platform to make use of electromagnetic conveyance. The manufacturing operations performed in the - dosing processes, are relatively simple, involving little or no loads, are relatively fast, repeatable, accurate and often involve multiple stations carrying out similar operations. However, the dosing operation in the capsule-filling manufacturing unit is dynamic, lending itself to running multiple batches in a dynamic, non-linear approach.

The entire process of capsule filling operation however involves multiple steps over and above merely dosing the capsules with dosing material. The process of capsule-filling manufacturing also involves the orientation, loading, separation recapping, and ejection of capsules. Each of the manufacturing operations are a distinct from the capsule dosing operation and carry a far higher risk of failure. The engineering tolerances are very small and the clearance between the capsule body and the capsule cap is less than 0.2mm. In addition to small clearance values, the capsule filling operation has to account for the capsules with inherent production variances, exacerbated by the need for high speed production output.

In a typical capsule filling operation, the highest risk for failure may be in the manufacturing operation unrelated to the dosing of the capsule. For example, the capsule loading operation may have a risk of the capsules not being correctly orientated and placed into the cap plate and the body plate prior to separation in a cap down orientation, or not loaded into the cap plate and the body plate. In capsule separation operation the capsules may not be completely split into their respective capsule caps and the capsule bodies. During the capsule separation operation, the capsule caps or the capsule bodies that are removed upon separation may leave the cap plate or the body plate with no capsule caps or capsule bodies in them., There may be capsule bodies not seated properly or lying on top of the body plate or capsule caps may still be present on top of the capsule bodies. During a capsule recapping operation, the misaligned capsule caps and capsule bodies may result in incomplete closure and may also lead to crushing of the capsules.

During the capsule dosing operation, the capsule bodies are dosed with a dosing material. However, if the body plate is not properly populated with defect free capsule bodies from the earlier capsule loading or separation operations due to missing, damaged or misaligned bodies, this will result in the dosing material being spilled on the CEMP or the body plate itself. This has a major impact resulting in contamination of not only the CEMP but potentially other stations. This results in stoppages for cleaning and potential production batch contamination. Any downstream processes including the capsule recapping operation also run the risk of contamination as the contaminated plates are introduced into the subsequent manufacturing operations. Thus, the risk of failure in any of the manufacturing operations has the potential to result in entire batch failure of all capsules in the capsule-filling manufacturing unit as well as the capsules already completed where the failure was not immediately identified. Further failure needs to be considered where undetected liquids and powders leaking from reject capsules may enter into larger batches including at point of bottling or packaging where further loss could be incurred.

Further, these high-risk and high-failure production operations involve handling of the capsule cap for performing one or more manufacturing operations. The handling of the capsule cap requires a focused approach involving the capsule cap and the cap plate to ensure high production accuracy, quality management, limitation of wastage, stoppages, and batch failure. To ensure high levels of engineering control over the capsule-filling manufacturing operation, and to limit the risk of failure, some of the operations such as capsule loading operation, capsule separation operation, capsule recapping operation, and capsule ejection operation are carried outside of the CEMP.

Existing CEMP manufacturing environments are highly automated systems that involve almost no human interventions suitable for predictable and accurate manufacturing. However, employing existing CEMP is restricted and not suitable for production environments where there is a need for operator correction. Capsule handling is a highly complex process that requires quick human intervention and is capable of assisting efficiency in the highly mechanical processes typically involved with the cap loading, separation and capsule recapping operations. Further, the risk of intervening in the electromagnetic area may result in the stoppage of all production activities, compromising the efficiency of the production operations.

Contactless Electromagnetic Manufacturing systems have highly efficient methods by which to track and direct the movement of individual magnetic movers on the electromagnetic plane. The tracking of the magnetic movers allows for dynamic routing and stacking of the capsules that are transported through different areas in the system. The tracking of the magnetic movers however may not handle in situations where there may be requirement of offline processes. The offline processes may include manufacturing operations such as loading individual body plates onto the magnetic movers that may be later tested for recipe fulfilment. The tracking and managing the movement of the cap plate and the body plate along with corresponding magnetic movers and production stations cannot be adequately matched, traced, and tested for meeting weight and other criteria required for recipe fulfilment in the capsule-filling manufacturing.

Further, in the existing Contactless Electromagnetic Manufacturing System, products are placed on the movers without providing any bottom accessibility. The movers are packed with rare earth magnets which are tightly bonded to one another these magnets are orientated in a particular direction and configuration essential to the operation of the electromagnetic transportation system. The construction of the movers restricts any modifications without affecting the mover's functionality. Thus, any manufacturing activities are to be carried out only by accessing the product from above as there is no bottom access available. The capsule-filling manufacturing requires bottom access for the capsules to vent, split, recap, and provide load and support from the bottom of the capsules during different stages of capsule-filling manufacturing operations such as capsule loading, capsule separation, capsule recapping, and capsule ejection. Therefore, the mover in the present Contactless Electromagnetic Manufacturing System is dedicated to only that of transportation on a surface in which production is carried out. This allows for all manufacturing activities to be carried out only by accessing the product from above. Thus, the electromagnetic system in its current configuration restricts users from having access below the product during manufacturing processes.

The major limitations in the existing Contactless Electromagnetic Manufacturing Systems for employing in the capsule-filling manufacturing unit are load bearing limitation and holding force limitation. The magnetic movers in the existing CEMS are only able to handle limited weights and product densities limiting its overall application in the capsule-filling manufacturing unit. The magnetic movers being complicated electromechanical equipment are very sensitive to load bearing capacities. Since in CEMS, the magnetic movers are moved and lifted using electromagnetic forces, the load bearing capacities are severely limited. When a material is dosed into containers held by the movers or performing a similar non-contact activity, the CEMS in its present configuration is able to cater for these immaterial levels of vertical force placed on the movers. In an example, the magnetic movers in the existing CEMS are capable of supporting a maximum weight of between 4.2kg and 6 kg. The loads involved in non-dosing operations are significantly higher than this rated weight. The existing CEMS may not able to resist any material level of vertical load on the mover, essential for these non-dosing related activities.

In capsule-filling manufacturing operations like capsule loading, capsule separation, capsule recapping and capsule ejection, a downward or holding force from top to bottom is exerted on the magnetic mover. In other manufacturing operations like capsule recapping and capsule ejection, an upward force from the bottom is exerted on the magnetic mover. The magnetic mover is required to provide a strong holding force by withstanding both the downward force and the upward force.. If the magnetic movers are unable to support the minimum vertical loading force, then the magnetic mover will then be pressed downward into the tiles, resulting in major damage to the tiles and the mover, impairing location control and accuracy, misalignment to production machinery, and product damage or failure. In the existing Contactless Electromagnetic Manufacturing Systems (CEMS), the magnetic mover fails to provide any provision which can actively support any upward force or any material downward force during such manufacturing operations. There is no mechanism available in the existing CEMS that provides stability to the mover subjected to both the upward force and the downward force. Thus, the limitation in load handling in the existing magnetic movers restricts overall application of the Contactless Electromagnetic Manufacturing System in capsule-filling manufacturing unit.

In manufacturing operations like capsule loading, separation, capsule recapping and capsule ejection, maintaining precise location of the body plate and the cap plate under the loads described above is essential to avoid migration or axial movement. Many of the production processes in the capsule-filling manufacturing unit deliver a large load vertically requiring lateral stability to perform production process accurately. The manufacturing operations in the capsule-filling manufacturing unit operate with extremely high tolerances that require considerable accuracy in lateral movement and strong axial stability resisting multiple forces. Typically, circumferential clearances between the inside of the capsule and the outside of the capsule body are approximately 20 microns. Since the clearances are narrow, any challenge with alignment or product variation may result in production failure. When placing the capsules under load, the risk of misalignment increases. Additionally, any lateral or axial inaccuracies will further increase the loading forces required to complete the manufacturing process, thereby exacerbating the alignment issues. Usually, the magnetic movers have stated weight loading capacities which are quoted only in the Z plane, given that these loads are a function of the main repulsive forces between the magnetic mover and the manufacturing plane. The forces delivered and the lateral movements in the X and Y planes are a function of variances between the electromagnetic motors within the tiles and are not capable of delivering the same control as in the Z plane. Therefore, the ability for the CEMS to control precise lateral positioning of the movers when placed under load is limited. This limited accuracy is not only in the X, Y and Z coordinates but also with the axial stability of the mover itself during production. The limited accuracy and axial stability of the mover in loaded conditions limits the accuracy, reliability, and quality of products manufactured on the CEMS. Therefore the existing CEMS systems may not be to perform the manufacturing operations with lateral or axial positioning accuracy sufficient to hold the capsules in place.

Generally, the CEMS allows for location tracking of the movers to identify where the mover is, where it came from, and where it needs to go in the electromagnetic area. Typically, to carry out different manufacturing operations, the movement of the mover might be programmed by the CEMS according to desired manufacturing protocols. Further, the routing of the movers may be then set by the CEMS based on the manufacturing protocols. The movement and tracking of the mover are enabled by assigning a designated address to a production area and a unique identification number for the mover. Similarly, the CEMS may set control points, durations, and actions at particular points as production is being carried out.

The implementation of CEMS in the capsule-filling manufacturing unit requires a high level of complexity involving knowing when the mover has arrived at the designated manufacturing station, how long it should be there in the designated manufacturing station, micro indexing, and other functions. Further, there are inter-station complexities that allow variable dosing per product requiring plates to move between multiple stations receiving multiple doses of products, addition of membranes, coatings, and other activities. It is therefore essential that all location, movement, dosing, and production activities in the capsule-filling manufacturing unit can be appropriately traced by both the CEMS and the production systems. Further, the level of integration between the CEMS and production systems is highly complex with high levels of risk such as maintaining accuracy in dosing delivered for a particular product. Further, there may be production processes that may be carried out only outside of the CEMS and the need to ensure tracking and management of the cap plate and the body plate throughout capsule-filling manufacturing unit is crucial. Both the production systems and the CEMS that manage production and the derived recipe for the particular product needs to match and track the capsules and their contents from dosing to ejection. It is therefore critical that there be both appropriate integration between production systems and the CEMS as well as a level of security, safety, and redundancy built into the manufacturing process. As the movers are not necessarily permanently attached to production components and given the need for in-production removal, cleaning, replacement, or other reasons, there is a significant risk of tracking movers and not the components holding the capsules.

Thus, in view of the above, it is desirable to provide an electromagnetic mover system that can eliminate one or more of the above-mentioned problems associated with existing art.

SUMMARY
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.

In an embodiment of the present disclosure, a capsule-filling manufacturing unit is provided. The capsule-filling manufacturing unit includes a capsule handling system and an electromagnetic mover system. The capsule handling system includes a plurality of stations adapted to perform a plurality of operations on at least one capsule loaded in a plate assembly, each station located in a non-electromagnetic area of the capsule-handling system. The capsule handling system further includes a capsule orientation and loading station from among the plurality of stations adapted to orientate and load capsules the plate assembly. A cap plate handling station from among the plurality of stations adapted to separate a cap plate from a body plate of the plate assembly separating a capsule cap from a capsule body. The cap plate is adapted to hold the capsule cap therein. The body plate is adapted to hold the capsule body and has a channel defined underneath the capsule body.

Further, the electromagnetic mover system is located outside the non-electromagnetic area and includes at least one magnetic mover, at least one electromagnetic area, and at least one handling mechanism. The non-electromagnetic area is adapted to provide a bottom passage to access the body plate to perform the plurality of operations in at least one of the plurality of stations, the at least one handling mechanism is adapted to transfer the body plate from the non-electromagnetic area to the electromagnetic area.

To further clarify the advantages and features of the present disclosure, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1A illustrates a first perspective view of an integrated capsule handling system with a Contactless Electromagnetic Manufacturing Systems (CEMS) in a capsule-filling manufacturing unit, emphasising a first set of operations, in accordance with an embodiment of the present disclosure;

Figure 1B illustrates a second perspective view of the integrated capsule handling system with the CEMS in the capsule-filling manufacturing unit, emphasising a second set of operations, in accordance with an embodiment of the present disclosure;

Figure 1C illustrates an isometric view of the integrated capsule handling system with the CEMS in the capsule-filling manufacturing unit showing a bottom passage, in accordance with an embodiment of the present disclosure;

Figure 2 illustrates a side view of the integrated capsule handling system with the CEMS in the capsule-filling manufacturing unit, emphasising the first set of operations, in accordance with an embodiment of the present disclosure;

Figure 3 illustrates an isometric view of a body plate positioned on a magnetic mover, in accordance with an embodiment of the present disclosure;

Figure 4 illustrates a sectional view of the plate assembly holding a plurality of capsules, in accordance with an embodiment of the present disclosure;

Figure 5 illustrates a perspective view of a capsule orientation and loading station, in accordance with an embodiment of the present disclosure;

Figure 6a illustrates a perspective view of a cap plate handling station, in accordance with an embodiment of the present disclosure;

Figure 6b illustrates an isometric view of the cap plate separated from a body plate at the cap plate handling station, in accordance with an embodiment of the present disclosure;

Figure 7 illustrates a perspective view of a capsule inspection station, in accordance with an embodiment of the present disclosure;

Figure 8 illustrates a perspective view of a recapping device, in accordance with an embodiment of the present disclosure;

Figure 9a illustrates a perspective view of a capsule ejection station, in accordance with an embodiment of the present disclosure; and

Figure 9b illustrates a planar view of the capsule ejection station, in accordance with an embodiment of the present disclosure.


DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

For example, the term "some" as used herein may be understood as "none" or "one" or "more than one" or "all." Therefore, the terms "none," "one," "more than one," "more than one, but not all" or "all" would fall under the definition of "some." It should be appreciated by a person skilled in the art that the terminology and structure employed herein is for describing, teaching, and illuminating some embodiments and their specific features and elements and therefore, should not be construed to limit, restrict or reduce the spirit and scope of the present disclosure in any way.

For example, any terms used herein such as, "includes," "comprises," "has," "consists," and similar grammatical variants do not specify an exact limitation or restriction, and certainly do not exclude the possible addition of one or more features or elements, unless otherwise stated. Further, such terms must not be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated, for example, by using the limiting language including, but not limited to, "must comprise" or "needs to include."

Whether or not a certain feature or element was limited to being used only once, it may still be referred to as "one or more features" or "one or more elements" or "at least one feature" or "at least one element." Furthermore, the use of the terms "one or more" or "at least one" feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, "there needs to be one or more…" or "one or more elements is required."

Unless otherwise defined, all terms and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by a person ordinarily skilled in the art.

Reference is made herein to some "embodiments." It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.

Use of the phrases and/or terms including, but not limited to, "a first embodiment," "a further embodiment," "an alternate embodiment," "one embodiment," "an embodiment," "multiple embodiments," "some embodiments," "other embodiments," "further embodiment", "furthermore embodiment", "additional embodiment" or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described therein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.

Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings. It should be understood that the drawings disclosed herewith are not to scale and nor should quantum and dimension be inferred from them.

Figure 1A illustrates a first perspective view of an integrated capsule handling system 100 with a Contactless Electromagnetic Manufacturing Systems (CEMS) in a capsule-filling manufacturing unit, emphasising a first set of operations, in accordance with an embodiment of the present disclosure. Figure 1B illustrates a second perspective view of the capsule handling system 100 with the CEMS in the capsule-filling manufacturing unit, emphasising a second set of operations, in accordance with an embodiment of the present disclosure. Figure 1C illustrates an isometric view of the integrated capsule handling system 100 with the CEMS in the capsule-filling manufacturing unit showing a bottom passage 128, in accordance with an embodiment of the present disclosure. Figure 2 illustrates a side view of the capsule handling system 100 with the CEMS in the capsule-filling manufacturing unit, emphasising the first set of operations, in accordance with an embodiment of the present disclosure. Figure 3 illustrates an isometric view of a body plate 302on a magnetic mover 112, in accordance with an embodiment of the present disclosure. Figure 4 illustrates a sectional view of the plate assembly 403 holding a plurality of capsules, in accordance with an embodiment of the present disclosure.

A capsule-filling manufacturing unit having a capsule handling system 100 integrated with a Contactless Electro Magnetic System (CEMS) is disclosed. The capsule-filling manufacturing unit typically involves a series of manufacturing operations carried out one after another in a production sequence in the capsule handling system 100 and the CEMS. The manufacturing operations in the capsule handling system 100 may include but not limited to capsule orientation, capsule loading, capsule separation, capsule recapping and capsule ejection. Each of the manufacturing operation may be carried out by a plurality of stations. Each of station in the plurality of stations may be located in a non-electromagnetic area 110 of the capsule handling system 100. Each station in the plurality of stations may be assigned to perform a specific manufacturing operation. The manufacturing operations are carried out sequentially in each of the plurality of stations in the capsule handling system 100.

In the illustrated embodiment, referring to Figures 1A and 1B, the plurality of stations may include, but is not limited to, at least one capsule orientation and loading station 118, at least one cap plate handling station 120, at least one capsule body detection station, at least one cap plate handling station 120, at least one capsule cap inspection station, at least one capsule body inspection station, at least one capsule weighing station 124, and at least one capsule ejection station 126, other stations and the number of stations used may be multiplied or combined in a manner appropriate for capsule-filling manufacturing. In an exemplary embodiment, the capsule orientation and loading station 118 may be adapted to orient and load capsules in a plate assembly 403. The capsule body inspection station may be adapted to detect the presence of capsule bodies 404 in the body plate 302. The cap plate handling station 120 may be adapted to separate a cap plate 401 from the body plate 302 of a plate assembly 403, store the cap plate 401 and combine the capsule cap 402 with the capsule body 404. The capsule body detection station may be adapted to detect the presence of capsule body 404 in the body plate 302. In one embodiment, the capsule body detection station may be a standalone separate station. In another embodiment, he capsule body detection station may be integrated into the capsule orientation and loading station 118 and the cap plate handling station 120. The capsule weighing station 124 may be adapted to weigh the capsule bodies 404 in the body plate 302. The capsule ejection station 126 may be adapted to eject the filled capsules identified as non-defective or compliant to a predefined production recipe and capsules identified as defective or non-compliant to the predefined production recipe from the plate assembly 403 based on the detection from the capsule inspection station 122.

The Contactless Electro Magnetic System (CEMS) may be integrated with the capsule handling system 100 in the capsule-filling manufacturing unit for carrying out some of the manufacturing operations. Hereafter, the CEMS may be interchangeably referred to as an electromagnetic mover system. The CEMS may include an electromagnetic area 108 formed by a plurality of connected tiles on a planar surface. Each tile in the plurality of connected tiles may be provided with electromagnet coils and electronic components that convert supplied energy into precisely regulated electromagnetic fields.

In an embodiment, the manufacturing operations carried out by the CEMS may include, but not limited to, capsule dosing operation. The CEMS may include at least one magnetic mover 112 that is adapted to be moved over the electromagnetic area 108. The magnetic mover 112 may be adapted to transport the body plate 302 to at least one capsule dosing station in the capsule-filling manufacturing unit. After the separation of the cap plate 401 from the body plate 302, the cap plate 401 is configured to be transported to at least one of the capsule dosing stations. The at least one capsule dosing station may be adapted to fill the capsule bodies 404 in the body plate 302 with the dosing material. In an embodiment, the dosing material may be one of, but not limited to, pharmaceutical, nutraceutical, supplements, and other materials, in various formats including powders, granules, beadlets, tablets, pellets, liquids, and other formats, suitable for oral dosage delivery. The manufacturing operations in the capsule handling system 100 may be improved dynamic stacking, storing of the cap plate 401, and independent recapping of the cap plate 401 with the body plate 302. Further, the capsule handling system may facilitate in achieving substantial optimization of manufacturing processes by accommodating rework, blockages, dynamic routing, and other optimization strategies.

Further, the magnetic mover 112 may be made up of a plurality of magnets, such as a matrix of rare earth magnets. The plurality of magnets may be stacked and glued together. Magnetic fields may be generated by the plurality of magnets in the magnetic mover 112. The generated magnetic field may push against the electro-magnetic force generated by the plurality of tiles of the electromagnetic area 108 resulting in the movement of the magnetic mover 112 above a surface of the tile. Further, the plurality of tiles may be incorporated with highly sensitive sensors to determine a precise location of the magnetic mover 112. The magnetic mover 112 may be moved omnidirectionally over the electromagnetic area 108 to the precise location. The arrangement of the electromagnetic tiles across the electromagnetic area 108 may be in one of square shaped, rectangular shaped, L-shaped, or annular systems and may also be further configurable. Furthermore, additional tiles may be added to the existing arrangement of the electromagnetic tiles to increase the electromagnetic area 108. The ability to add additional tiles may provide modularity and offers a high level of flexibility for designing scalable and flexible production system.

Further, the capsule handling system 100 may be provided with at least one handling mechanism adapted to transfer the body plate 302 from the non-electromagnetic area 110 to the electromagnetic area 108 upon completion of a first set of operations. Furthermore, the at least one handling mechanism may be adapted to re-transfer the body plate 302 from the electromagnetic area 108 to the non-electromagnetic area 110 such that a second set of operations are performed on the body plate 302. In an embodiment, the at least one handling mechanism may include a first handling mechanism 102 adapted to transfer the plate assembly 403 from the capsule ejection station 126 to the capsule loading station, from among the plurality of stations, to perform the first set of operations. In a non-limiting embodiment, the first set of operations includes a capsule loading operation, a capsule detection operation, a capsule separation operation, a cap plate 401 transfer operation, and a cap plate 401 storing operation. In an embodiment, the at least one handling mechanism may include a second handling mechanism 104 adapted to transfer the body plate 302 from the non-electromagnetic area 110 to one of the magnetic mover 112 in the electromagnetic area 108 after completion of the first set of operations and re-transfer the body plate 302 from the electromagnetic area 108 to the non-electromagnetic area 110 to perform the second set of operations. In a non-limiting embodiment, the second set of operations may include a capsule body inspection operation, a capsule recapping operation, a capsule weighing operation, and a capsule ejection operation. In an exemplary embodiment, the at least one handling mechanism may be a robotic arm, without departing from the scope of the present disclosure.

Further, it is to be understood that the integrated capsule handling system 100 in the CEMS illustrated in the figures 1A and 1B are exemplary. The dimensions and size of the stations and the CEMS as depicted in figures 1A and 1B should not be construed as limiting. The size of the stations, the number of stations, the number of cap plate and the body plate and the number magnetic movers may vary during implementation of the capsule handling system 100 in the CEMS. Although the capsule dosing station is not shown in Figures 1A and 1B, however it is to be understood that a plurality of capsule dosing stations may be provided in the capsule-filling manufacturing unit.

Further, the cap plate 401 and the body plate 302 may be aligned together to form a capsule cavity. The cap plate 401 and the body plate 302 may be disposed with a plurality of cavities. The plurality of cavities in the cap plate 401 aligns with the plurality of cavities in the body plate 302 to form a capsule cavity. The capsule cavity may be formed by the alignment of the plurality of cavities in the cap plate 401 and the plurality of cavities in the body plate 302 such that capsules are received therein. The cap plate 401 may be adapted to hold a capsule cap 402 in each of the cavity defined around each capsule cap 402 held in the cap plate 401. Similarly, the body plate 302 may be adapted to hold the capsule body 404 in each of the cavity defined around each capsule body 404 held in the body plate 302. The body cavity 302 may have a channel 406 defined underneath each capsule body 404 held in the body plate 302. Furthermore, the cap plate 401 may be positioned on the body plate 302 and adapted to be engaged with each capsule cap 402 corresponding to each capsule body 404 resting in the body plate 302.

The cap plate 401 and the body plate 302 may be aligned together to form the plate assembly 403. Further, the plate assembly 403 may include a alignment mechanisms to align the body plate 302 with the cap plate 401. The body plate 302 may include a plurality of second alignment elements positioned on a peripheral region of the body plate 302 and the cap plate 401 may include a plurality of first alignment elements. The first alignment elements in the cap plate 401 may be adapted to be coupled with the second alignment elements in the body plate 302. Further, a contour of each first alignment element conforms with a contour of each second alignment element. In an embodiment, the first alignment element may be embodied as a raised formation, a recessed formation, or a combination of both. Further, the second alignment element may be embodied as a raised formation, a recessed formation, or a combination of both.

In one embodiment, the first alignment mechanism may include at least two or more raised formations formed on the body plate 302. Each raised formation is adapted to be received within a respective recess provided on the cap plate 401 such that the body plate 302 is aligned with the cap plate 401.

In another embodiment, the first alignment mechanism may include at least two or more raised formations formed on the cap plate 401. Each raised formation is adapted to be received within a respective recess provided on the body plate 302 such that the cap plate 401 is aligned with the body plate 302.

In yet another embodiment, the first alignment mechanism may include at least one raised formation and at least one recess formed on the body plate 302, and corresponding at least one raised formation and at least one recess may be provided on the cap plate 401. Each raised formation in the body plate 302 may be adapted to be received within a respective recess provided on the cap plate 401 and each raised formation in the cap plate 401 may be adapted to be received within a respective recess provided on the body plate 302 such that the body plate 302 is aligned with the cap plate 401. In yet another embodiment, a contour of a periphery of the cap plate 401 conforms with a contour of the periphery of the body plate 302, such that the cap plate 401 is aligned with the body plate 302.

Further, a second alignment mechanism may be provided to align the body plate 302 with the magnetic mover 112. The body plate 302 may include a plurality of second alignment elements positioned on a peripheral region of the body plate 302 and the magnetic mover 112 may include a plurality of first alignment elements. The first alignment elements in the magnetic mover 112 may be adapted to be coupled with the second alignment elements in the body plate 302. Further, a contour of each first alignment element conforms with a contour of each second alignment element. In an embodiment, the first alignment element may be embodied as the raised formation, the recess, or a combination of both. Similarly, the second alignment element may be embodied as the raised formation, the recess, or a combination of both.

In one embodiment, the second alignment mechanism may include at least two or more raised formations formed on the body plate 302. Each raised formation is adapted to be received within a respective recess provided on the magnetic mover 112 such that the body plate 302 is aligned with the magnetic mover 112.

In another embodiment, the second alignment mechanism may include at least two or more raised formations formed on the magnetic mover 112. Each raised formation is adapted to be received within a respective recess provided on the body plate 302 such that the magnetic mover 112 is aligned with the body plate 302.

In yet another embodiment, the second alignment mechanism may include at least one raised formation and at least one recess formed on the body plate 302 and corresponding at least one raised formation and at least one recess may be provided on the magnetic mover 112. Each raised formation in the body plate 302 may be adapted to be received within a respective recess provided on the magnetic mover 112 and each raised formation in the magnetic mover 112 may be adapted to be received within a respective recess provided on the body plate 302 such that the body plate 302 is aligned with the magnetic mover 112.

In yet another embodiment, a contour of a periphery of the magnetic mover 112 conforms with a contour of the periphery of the body plate 302, such that the magnetic mover 112 is aligned with the body plate 302.

In an embodiment, the raised formation of the first and the second alignment mechanisms may have different shapes, such as a cylindrical shape, a cuboidal shape, a conical shape, or any other shape known in the art, without departing from the scope of the present disclosure. Further, a shape of the recess may conform with the shape of the corresponding raised formation. The recess may have different shapes, such as a cylindrical shape, a cuboidal shape, a conical shape, or any other shape known in the art, without departing from the scope of the present disclosure. The embodiments disclosed herein should not be construed as limiting and different alignment mechanisms may be employed to align the cap plate 401, the body plate 302, and the magnetic mover 112.

Further, the non-electromagnetic area 110 is provided with a first plate mover 114 and a second plate mover 116. The first plate mover 114 and the second plate mover 116 are disposed parallel to each other across the plurality of stations. The first plate mover 114 may be configured to aid movement of one of the plate assembly 403 and the body plate 302 to perform the first set of operations. The second plate mover 116 may be configured to aid movement of one of the plate assembly 403 and the body plate 302 to perform the second set of operations.

In a non-limiting embodiment, the first plate mover 114 and the second plate mover 116 may be guide rails or conveyer paths, without departing from the scope of the present disclosure. The embodiments disclosed herein should not be construed as limiting and different moving mechanisms may be employed to move the one of plate assembly 403 and the body plate 302 in the non-electromagnetic area 110.

Further, the non-electromagnetic area 110 may be provided with a bottom passage 128 to access the body plate 302 from below in order to perform the plurality of operations in at least one of the plurality of stations. The bottom passage 128 may be defined below the plate assembly 403 or the body plate 302 in the first plate mover 114 or the second plate mover 116 such that a plurality of recesses for holding a plurality of capsule bodies 404 in the body plate 302 is accessible via the channel 406 The disposal of the body plate 302 above the first plate mover 114 and the second plate mover 116 facilitates in accessing each capsule body 404 via the channel 406 from below through the bottom passage 128.

Further, each station in the non-electromagnetic area 110 may be adapted to perform a specific assigned operation. The capsule orientation and loading station 118 may be adapted to orient the capsule in an intended direction and load the capsule into the capsule cavity such that the capsule cap 402 is inserted into the cap plate 401 and the capsule body 404 is inserted into the body plate 302. The capsule body detection station may be adapted to detect that the capsules are fully populated in the capsule cavity of the plate assembly 403. The cap plate handling station 120 may be adapted to separate the cap plate 401 and the body plate 302 and store the separate cap plate 401 in a cassette arrangement. The cap plate handling station 120 may further be adapted to recouple the cap plate 401 with the body plate 302 as well as provide the resistive upward force necessary to hold the cap plate 401 in place during the capsule recapping operation. The capsule inspection station 122 is adapted to inspect and detect defects in the capsule bodies 404 held by the body plate 302. The capsule weighing station 124 may be adapted to weigh each of the capsule bodies 404 held in the body plate 302. The capsule ejection station 126 adapted to eject the capsules from the plate assembly 403 based on the detection from one of the capsule weighing station 124 and capsule inspection station 122. The capsule handling system 100 may contain additional stations that may perform a variety of additional functions to best make use of the accuracy, load bearing and bottom access features uniquely suited to the capsule handling system 100. The additional functions may include but not limited to insertion of membranes, application of coatings or other functional activities relevant to capsule dosing. The working mechanism of the operations performed by each of the station is described in detail in subsequent paragraphs.

Figure 5 illustrates a perspective view of the capsule orientation and loading station 118, in accordance with an embodiment of the present disclosure. In an embodiment, the plate assembly 403 may be adapted to be placed over the first plate mover 114 in the non-electromagnetic area 110 by the first handling mechanism 102. The plate assembly 403 may be picked up from the capsule ejection station 126 after completion of the second set of operations and placed at the capsule orientation and loading station 118 to perform the first set of operations. The plate assembly 403 may be placed over the first plate mover 114 by the first handling mechanism 102. The plate assembly 403 may be moved over to the first plate mover 114 to the capsule orientation and loading station 118 from among the plurality of stations.

Further, at the capsule loading station, the plurality of capsules may be dispensed from a hopper 502 into the capsule cavity formed between the cap plate 401 and the body plate 302. The plurality of capsules may be dispensed in the cap plate 401 positioned over the body plate 302 such that the capsule cap 402 is located within the cap plate 401 and the capsule body 404 is located within the body plate 302. Each of the plurality of cavities in the cap plate 401 is provided with a ridgeline formation at the base of the cavity. The ridgeline in the plurality of cavities of the cap plate 401 may be narrower than an external diameter of the capsule cap 402 and larger than the capsule body 404. During the capsule loading operation, when the capsules are dispensed into the capsule cavity, the ridgeline provides a surface for the capsule cap 402 to rest and limits the capsules from falling through the cap plate 401 and the body plate 302.

Further, when the capsules are dispensed into the capsule cavity, the volume of each capsule displaces an empty volume inside each of the capsule cavity creating a buildup of back pressure. The back pressure built up during the capsule loading process may be vented out into the bottom passage 128 via the base of the body cavity through the channel 406 of the body plate 302. In particular, during loading of the capsules, the bottom passage 128 defined below the body plate 302 in the first plate mover 114 allows for releasing the back pressure to an ambient environment.

Further, a vacuum device 202 may be disposed in the capsule orientation and loading station 118 below the first plate mover 114. The vacuum device 202 may be disposed with a plurality of ports adapted to be in connection with the body plate 302 from the bottom passage 128 via the open ends of the channel 406 in the body plate 302. The plurality of ports in the vacuum device 202 may be adapted to apply a downward force in each channel 406 to pull the capsule into the capsule cavity. In an embodiment, the downward force may be a vacuum applied by the plurality of ports onto the open end of the channel 406 in the body plate 302. The downward force facilitates in guiding or positioning the capsules into the capsule cavity. The capsule may be pulled into the plurality of cavities in the cap plate 401 and the body plate 302 respectively, by the downward force. In an embodiment the vacuum provided by the vacuum device 202 may be sufficient to separate the capsule body 404 from the capsule cap 402 without need for a capsule separation station.

Further, the capsule orientation and loading operation may require vertical alignment of the plate assembly 403, the plurality of ports of the vacuum device 202. The vacuum device 202 and the plate assembly 403 may be laterally braced with support structures and alignment mechanisms such as linear bearings and support gantries, to ensure no migration, movement or misalignment takes place during the capsule loading operation. Furthermore, during the capsule loading operation , the support structures and the alignment mechanisms in the capsule orientation and loading station avoid damage or destruction of the capsules.

In a preferred embodiment, the capsule body detection station may be a separate standalone station. After the capsule orientation and loading station 118, the plate assembly 403 may be adapted to be moved over the first plate mover 114 in the non-electromagnetic area 110 to the capsule body detection station from among the plurality of stations. In an embodiment, the vacuum device 202 may be disposed in the capsule body detection station below the first plate mover 114. The vacuum device 202 may be disposed with the plurality of ports adapted to be in connection with the body plate 302 from the bottom passage 128 via the open ends of the channel 406 in the body plate 302. The vacuum may be applied via the plurality of ports by the vacuum device 202 to each channel 406 of the body plate 302 to detect the presence of the capsules in the plate assembly 403. Further, the vacuum device 202 may be provided with a sensor to detect incorrect loading, orientation or seating of the capsules in the plate assembly 403. The failures in such operations may be identified by low vacuum pressure, indicative of poorly seated bodies allowing airflow to restrict the vacuum build-up .In one embodiment, the vacuum device 202 may be provided in the capsule body detection station for detecting the capsule bodies 404. In another embodiment, the capsule body detection station may be integrated with the capsule orientation and loading station 118 and detected for capsule bodies 404 in the body plate 302.

Figure 6a illustrates a perspective view of the cap plate handling station 120, in accordance with an embodiment of the present disclosure. Figure 6b illustrates an isometric view of the cap plate 401 separated from the body plate 302 in the cap plate handling station 120, in accordance with an embodiment of the present disclosure. After the capsule body detection station, the plate assembly 403 may be adapted to be moved over the first plate mover 114 to the cap plate handling station 120 from among the plurality of stations. At the cap plate handling station 120, the capsule cap 402 and the capsule body 404 may be separated in two stages. Firstly, the capsule body 404 may be separated from the capsule cap 402 by application of the downward force by the vacuum device 202 in holding down the capsule bodies 404 within the body plate 302. Secondly, the capsule cap cavities contained within the cap plate 401 having ridgeline formations below the capsule cap 402 thereby capable of securing the capsule cap 402. The capsule cap 402 may be separated by removal of the cap plate 401 from the body plate 302 in the plate assembly 403. The cap plate 401 may be adapted to be engaged with a gripper 602 and lifted vertically by the gripper 602. The vacuum device 202 may apply the downward force on each capsule body 404 through the channel 406 resisting the capsule body 404 from following the capsule cap 402, such that each capsule cap 402 is separated from each capsule body 404. In an embodiment, the downward force is a vacuum applied by the plurality of ports onto the open end of the channel 406 in the body plate 302.

After the application of the vacuum by the vacuum device 202, the cap plate 401 may be engaged by the gripper 602 and adapted to be lifted in an upward direction with respect to the body plate 302. The combination of applying downward force by the vacuum device 202 and the lifting of the cap plate 401 by the gripper 602 facilitates in separating the capsule cap 402 from the capsule body 404. Further the capsule cap inspection station from among a plurality of stations may be integrated into the cap plate handling station 120. The capsule cap inspection station may be adapted to detect the presence of the capsule cap 402 in the cap plate 401 through an optic sensor to identify missing capsule caps 402. Further, the cap plate 401 separated from the plate assemblies are stacked in the cassette arrangement in the cap plate handling station 120 such that any one of the cap plate 401 is recoupled with any one of the body plate 302 during the capsule recapping operation.

Further, the capsule separation operation may require vertical alignment of the body plate 302, the cap plate 401, the plurality of ports in the vacuum device 202. The body plate 302, the cap plate 401, the plurality of ports in the vacuum device 202 may be laterally braced with support structures and alignment mechanisms such as linear bearings and support gantries, to ensure no migration, movement or misalignment takes place during the capsule separation operation. Furthermore, during the capsule separation operation, the support structures and the alignment mechanisms in the cap plate handling station 120 avoid the damage or destruction of the capsules or incomplete separation of the capsules.

In a preferred embodiment, the capsule body inspection station may be a separate standalone station. Further, preceding to transferring the body plate 302 to or from the non-electromagnetic area 110, the body plate 302 may be adapted to be moved over the first plate mover 114 to the capsule body inspection station from among the plurality of stations. At the capsule body inspection station, the vacuum device 202 or an optical sensing device 204 may be configured to detect that the plurality of recesses in the body plate 302 is fully populated with the capsule bodies 404, in an undamaged and correctly positioned state. The vacuum device 202 may detect the capsule bodies 404 from a bottom portion of the body plate 302 and the optical sensing device 204 may detect the capsule bodies 404 from a top portion of the body plate 302. The vacuum device 202 and the optical device may be adapted to detect uneven split caps or bodies, dented, damaged, misaligned or improperly loaded capsule bodies 404 during the capsule separation operation, irregularly shaped capsule bodies 404, or contaminated capsule bodies 404. In another embodiment, the capsule body inspection station may be integrated with the cap plate handling station 120.

Further, the non-electromagnetic area 110 may be provided with at least one operator station 106 where any one of the body plate 302 may be diverted for manual intervention. The at least one operator station 106 may be adapted to allow performing corrective action by an operator whilst the capsule handling system 100 continue to operate without stoppages, preceding to transferring the body plate 302 to the electromagnetic area 108 and ensuring that all the body plates 302 are compliant before they run the risk of contamination and batch failure. The at least one operator station 106 may be located on periphery of the non-electromagnetic area 100 whilst the operators have limited access to the cap plate handling station 120 plates are diverted from the production stations as failure is detected to the operator station to resolve any issues on any of the individual body plate 302 or the plate assembly 403 prior to transportation to electromagnetic area 110. The operator station 106 provides operator access enabling manual intervention if needed. For example, if one of the body plate 302 found to be not properly separated from the cap plate 401, leaving uneven separation of the capsule cap 402 from the capsule body 404, the operator may manually intervene and remove the damaged body plate 302 from the production line.

After the capsule body inspection station, the second handling mechanism 104 may be adapted to transfer the body plate 302 from the first plate mover 114 in the non-electromagnetic area 110 to the one of the magnetic movers 112 in the electromagnetic area 108. The magnetic mover 112 may be adapted to transfer the body plate 302 to one or more capsule dosing stations to fill the capsule body 404 with one or more dosing materials. A capsule dosing operation may be carried out in the one or more capsule dosing stations. The capsule dosing stations may be adapted to fill the capsule body 404 with a variety of materials in powder, beadlet, granular, liquid, or other form. In an embodiment, the capsule dosing operation may also be carried out over a number of different dosing stations to facilitate multiple ingredient dosing. In a non-limiting embodiment, additional activities may take place in the capsule dosing station such as insertion of membranes to separate the body compartments, applying coatings and any other activities relevant to capsule dosing process.

The magnetic mover 112 is adapted to move between one or more capsule dosing stations to fill with the dosing materials and adapted to return proximal to the non-electromagnetic area 110 once filled. When the magnetic mover 112 returns in proximity to the to the non-electromagnetic area 110, the second handling mechanism 104 may be adapted to lift the body plate 302 from the magnetic mover 112 in the electromagnetic area 108 and place it on the second plate mover 116 in the non-electromagnetic area 110

Figure 7 illustrates a perspective view of the capsule inspection station 122, in accordance with an embodiment of the present disclosure. After being placed by the second handling mechanism 104 onto the second plate mover 116, the body plate 302 may be adapted to be moved over the second plate mover 116 to the capsule inspection station 122. At the capsule inspection station 122, the body plate 302 may be monitored by an optical sensing device 204 to detect defects in capsule bodies 404 held by the body plate 302. The optical device may be adapted to detect one of dented or damaged capsule bodies 404 during the capsule separation operation, irregularly shaped capsule bodies 404 and contaminated capsule bodies 404 during capsule dosing operation. The optical sensing device 204 may be adapted to monitor the body plate 302 through the bottom passage 128 for a bottom inspection and from a top portion of the body plate 302 for a top inspection.

After the capsule inspection station 122, the body plate 302 may be adapted to be moved over the second plate mover 116 to the capsule weighing station 124. At the capsule weighing station 124, the capsule bodies 404 are weighed via a load sensor provided in the bottom passage 128 below the plate assembly 403. The load sensor may be adapted to access each of the capsule bodies 404 in the body plate 302 via the channel 406 in the body plate 302. In one embodiment, each of the capsule bodies 404 in the body plate 302 is individually detected for target weights and validated for predefined production recipes in the capsule weighing station 124. In another embodiment, all of the capsule bodies 404 may be detected collectively for target weights and validated for predefined production recipes in the capsule weighing station 124.

Figure 8 illustrates a perspective view of a recapping device 800 in accordance with an embodiment of the present disclosure. After the capsule weighing station 124, the body plate 302 may be adapted to be moved over the second plate mover 116 to the cap plate handling station 120 from among the plurality of stations. At the cap plate handling station 120, the separated cap plate 401 may be adapted to be removed from the cassette arrangement and retained on the body plate 302 by the gripper 602 forming the plate assembly 403. In the illustrated embodiment, the recapping device 800 may be provided with a plurality of recapping pins 802 and may be actuated in a vertical direction. The recapping device 800 may be adapted to be positioned in the bottom passage 128 of the second plate mover 116. During the capsule recapping operation, the plate assembly 403 may be aligned with the plurality of recapping pins 802 of the recapping device 800 in the bottom passage 128. The plurality of recapping pins 802 may be adapted to apply an upward force on each capsule body 404 in the body plate 302. Further, the gripper 602 plate may be adapted to resist the upward force, such that the capsule cap 402 and the capsule body 404 are recapped to form the capsule.

As earlier mentioned, the cap plate 401 holding the capsule cap 402 has the ridgeline supporting the open ends of the capsule cap 402. The ridgeline in the cap plate 401 formation limits the capsule cap 402 from falling through the cap plate 401. Due to the presence of the ridgeline in the cap plate 401, the capsule cap 402 and the capsule body 404 may not be rejoined by pushing the capsule cap 402 down onto the capsule body 404. Rather, the capsule body 404 may be pushed upwards into the capsule cap 402 by the plurality of recapping pins 802 from the recapping device 800. The bottom passage 128 below the body plate 302 in the second plate mover 116 enables the vertical movement of the plurality of recapping pins 802 through the plate assembly 403.

Further, in order for the capsule cap 402 and the capsule body 404 to remain firmly engaged with one another and avoid separation and spillage, both the capsule cap 402 and the capsule body 404 have circumferentially profiled ridge formations designed to mate the capsule cap 402 and capsule body 404 to one another. The process of recapping the capsule cap 402 with the capsule body 404 involves deforming sidewalls of the capsule cap 402 and the capsule body 404 until they engage with one another in a mated arrangement. The plurality of recapping pins 802 may be adapted to deliver a predefined amount of the upward force applied to the capsule bodies 404 and the gripper 602 plate may be adapted to resist the upward force to enable attachment of the capsule cap 402 with the capsule body 404. In an embodiment, the predefined amount of the upward force applied by the plurality of recapping pins 802 is at least 25 newtons.

Further, the capsule recapping operation may require vertical alignment of the body plate 302, the cap plate 401, the plurality of recapping pins 802. The gripper 602 and the second plate mover 116 and the recapping device 800 may be laterally braced with support structures and alignment mechanisms such as linear bearings and support gantries, to ensure no migration, movement or misalignment takes place during the capsule recapping operation. Furthermore, during the capsule recapping operation , the support structures and the alignment mechanisms in the cap plate handling station 120 avoid the damage or destruction of the capsules or incomplete recapping of the capsule which may result in leaking of the capsules and contamination of large production batches.

Figure 9a illustrates a perspective view of the capsule ejection station 126, in accordance with an embodiment of the present disclosure. Figure 9b illustrates a side view of the capsule ejection station 126, in accordance with an embodiment of the present disclosure. After the cap plate handling station 120, the body plate 302 may be adapted to be moved over the second plate mover 116 to the capsule ejection station 126 from among the plurality of stations. At the capsule ejection station 126, the capsules are ejected from the plate assembly 403 based on the detection from one of the capsule inspection station 122 or the capsule weighing station 124. In an embodiment, an ejection device may be provided with a plurality of ejection pins and may be actuated in a vertical direction. The ejection device may be adapted to be positioned in the bottom passage 128 of the second plate mover 116. During the capsule ejection operation, the plate assembly 403 may be aligned with the plurality of ejection pins of the ejection device in the bottom passage 128. In an embodiment, the constructional and operation features of the ejection device is similar to the recapping device 800 illustrated in figure 8.

Further, the plurality of ejection pins may be adapted to apply an upward force on each capsule body 404 such that the capsule is ejected from the plate assembly 403. The capsule ejection station 126 is adapted to selectively actuate pins to eject capsules identified as non-defective and compliant from the plate assembly 403 based on the detection from one of the capsule inspection station 122, the capsule body inspection station, or the capsule weighing station 124. The identified non-defective and compliant capsules may be ejected in a production bin and may proceed for post-production. Further, the capsule ejection station 126 may be adapted to selectively actuate pins to eject capsules identified as defective or non-compliant from the plate assembly 403 based on the detection from one of the capsule inspection station 122 or the capsule weighing station 124. The identified defective or non-compliant capsules may be ejected into a waste bin and may be discarded.

Further, the capsule ejection operation may require vertical alignment of the body plate 302, the cap plate 401, the plurality of ejection pins. The body plate 302, the cap plate 401, the plurality of ejection pins may be laterally braced with support structures and alignment mechanisms such as linear bearings and support gantries, to ensure no migration, movement or misalignment takes place during the capsule ejection operation. Furthermore, during the capsule ejection operation, the support structures and the alignment mechanisms in the capsule ejection station 120 avoid the damage or destruction of the capsules or incomplete ejection of the capsule which may result in leaking of the capsules and contamination of large production batches.

Further, the capsule-filling manufacturing unit may be provided with a machine management system. The machine management system may be configured to identify the body plate 302 by receiving an input from the second handling mechanism 104. The body plate 302 may be configured to be identified by the second handling mechanism 104 when returned proximal to the non-electromagnetic area 110 by the magnetic mover 112. Further, the machine management system may track the body plate 302 and corresponding magnetic mover 112 in the capsule-filling manufacturing unit. The magnetic mover 112 and the body plate 302 are directed towards the one or more capsule dosing stations to dose into the capsule bodies 404 based on a predefined recipe. The one or more capsule dosing station may identify the body plate 302 to ensure the correct body plate 302 for the production batch may be arrived at the capsule dosing station. The capsule dosing station and second handling mechanism 104 may be provided with a scanner to scan a unique identifier from the body plate 302 and the magnetic mover 112. In an embodiment, the identifier may be one of, but not limited to, a barcode, a Radio Frequency (RF) tag, and any other means of identification. When the body plate 302 is transferred to the capsule dosing station, the machine management system may determine the quantity of material that needs to be dosed in the capsule bodies 404 carried by the identified body plate 302. The identification of the body plate 302 enables the machine management system to individually map the capsule bodies 404 with the materials or ingredients dispensed during the capsule dosing process.

Further, after dosing the capsule bodies 404 with the dosing materials, the body plate 302 may be returned proximal to the non-electromagnetic area 110 by the magnetic mover 112. The body plate 302 may be identified by the second handling mechanism 104 upon retrieval from the magnetic mover 104. Upon identifying the body plate (302) returning to the second plate mover (116), the machine management system may be configured to compare the weight of the capsule bodies (404) identified by the capsule weighing station (124) with the target weight of the predefined recipe. When the identified weight of the capsule bodies (404) is equal to the predetermined target weight, the machine management system validates the body plate (302) for production compliance and proceeds for further manufacturing operations.

Further, by identifying the body plate 302, the machine management system may also track dosing of any of the capsule bodies 404 by mapping the capsule bodies 404 with the respective magnetic mover 112. Furthermore, the identification of the body plate 302 and the corresponding magnetic mover 112 enables the machine management system to test and track compliance of each body plate 302 returned from the capsule dosing station to a predefined production recipes. Moreover, the individual tracking of the body plate 302 enables for processing multiple products simultaneously and allows for variable dosing in the capsule dosing stations.

The advantages of the capsule-filling manufacturing unit having the capsule handling system 100 integrated with the CEMS are explained below. The capsule-filling manufacturing unit integrates the CEMS with the non-electromagnetic manufacturing procedures by optimising the features of the electromagnetic manufacturing procedures while retaining load bearing, high tolerance and bottom access features of the non-electromagnetic portion. The integration further optimises the use of the CEMS to the highest throughput, quality and minimising rejects.

The integration of the electromagnetic area 108 in the CEMS with the non- electromagnetic area 108 in the capsule handling system 100 provides for a highly automated process involved in the production activities. The integration reduces the complexity associated with electromagnetic production with and eliminates failure and contamination. Additionally, by being able to optimize handling of the cap plate 401, resolution of failure through intervention is streamlined. The separate handling of the cap plate 401 allows the capsule-filling manufacturing operations to be optimized allowing maximum efficiency through the supply of higher volumes of body plates 302 as well as error free bodies that can be efficiently processed. The separate handling of the cap plate 401 also improves both quantity and quality of the overall production output of the capsule handling system 100.

Accessing the bottom of the capsule is crucial to carry out key manufacturing operations in the capsule handling system 100 not achievable with the Contactless Electromagnetic Production Systems (CEMS). The bottom passage 128 defined in the non-electromagnetic area 110 allows for accessing the bottom of the capsules. Owing to such constructional details, the capsule handling system 100 as disclosed in the present disclosure allows to perform each of the manufacturing operations. Firstly, during capsule loading operation, the bottom passage 128 in the non-electromagnetic area 110 allows to vent the back pressure and may facilitate the application of the vacuum to guide the capsules into the capsule cavity. Secondly, during the capsule separation operation, the bottom passage 128 in the non-electromagnetic area 110 allows the vacuum device 202 to apply vacuum via the open end of the channel 406 in the body plate 302. Thirdly, during vacuum sensing either in independent capsule detection stations or as incorporated into either the capsule loading or cap plate handling station 120, the measuring of vacuum pressure from below the capsule bodies 404 to determine presence, correct orientation or deformation. Fourthly during the capsule recapping operation, the bottom passage 128 in the non-electromagnetic area 110 allows the recapping device 800 to push the plurality of capsule bodies 404 against the plurality of capsule cap 402s. Fifthly, during capsule inspection operation, the bottom passage 128 in the non-electromagnetic area 110 allows for the optical sensing device 204 to detect the capsule bodies 404. Sixthly, during capsule weighing operation, the bottom passage 128 in the non-electromagnetic area 110 accommodates load sensors to individually detect the weight of each capsule body 404 in the body plate 302. Seventhly, during capsule ejection operation, the recapping device 800 is positioned below the body plate 302 in the bottom passage 128, and the plurality of ejection pins is pushed through the open end of the channel 406 to eject the capsules.

The manufacturing operations in the capsule handling system 100 deliver a large load vertically requiring lateral stability of the plate assembly 403, the vacuum device 202and the gripper 602 or any such components required to perform production process accurately. The capsule handling system 100 provides for precise lateral positioning of such components under load conditions. The support structures and alignment mechanisms such as linear bearings and support gantries provide considerable accuracy in lateral movement and provide strong axial stability resisting multiple forces. The improved accuracy and axial stability of the different components in loaded conditions assures reliability, and quality of products manufactured by the capsule handling system 100.

Further, the support structures and the gantries provided in each of the stations provide structural support to one of the body plate 302 and the plate assembly 403. Many of the production operations in the capsule handling system 100 deliver multiple forces that require lateral, vertical, and axial stability to perform the production process accurately. The plate assembly 403 or the body plate 302 may be required to withstand the multiple forces and provide the lateral, vertical, and axial stability to perform different manufacturing operations. The plate assembly 403 or the body plate 302 by itself may not be capable of providing the required stability during the manufacturing operations. The support structure and the gantries in each of the stations may be adapted to provide the required stability to the one of the plate assembly 403 and the body plate 302 during the manufacturing operations in the capsule handling system 100. The support structure and the gantries in each of the stations may resist the lateral and vertical movement of the plate assembly 403 and the body plate 302 during any of the manufacturing operations.

Further, the capsule-filling manufacturing unit as disclosed herein provides for failure detection through various inspection and detection systems during the production process. The capsules are detected by the vacuum device 202 after the capsule loading operation to ensure the capsules are fully populated in the plate assembly 403. Further, the body plate 302 may be detected by the vacuum device 202 in the capsule body detection station to detect uneven split capsule cap 402s or capsule bodies 404 ensuring all the capsule cap 402 are separated from the corresponding capsule bodies 404. Furthermore, after returning from the capsule dosing station, the body plate 302 is inspected by the optical sensing device 204 in the capsule inspection station 122 to ensure the body plate 302 is free from contamination and the capsule weighing stations is able to weigh all capsules to ensure that they are in compliance with formulations and meet regulatory and safety standards. The various detection and inspection stations allows to detect the defective and non-compliant capsules during the production operations.

Further, the capsule handling system 100 as disclosed herein provides for selective ejection of capsules confirming to the predefined production recipes. The capsules are ejected from the plate assembly 403 based on the detection from one of the capsule inspection station 122 or the capsule weighing station 124. The capsule ejection station 126 is adapted to selectively eject capsules identified as non-defective and compliant from the plate assembly 403 based on the detection from one of the capsule inspection station 122, or the capsule weighing station 124. The identified non-defective and compliant capsules may be ejected in a production bin and may proceed for post-production. Further, the capsule ejection station 126 may be adapted to selectively reject the capsules identified as defective or non-compliant from the plate assembly 403 based on the detection from one of the capsule inspection station 122 or the capsule weighing station 124. Thu, the capsule handling system 100 provides for selective ejection and rejection confirming to the predefined production recipes.

Further, any manufacturing operation resulting in non-compliant production, runs the risk of suffering from traditional linear manufacturing stoppages. To resolve any manufacturing related issues, an operator may need to reach the non-electromagnetic area 110, resulting in the stoppage of the capsule- filling manufacturing operations. However, the operator station 106 provided in the present disclosure allows to resolve any issues on individual plates in a highly efficient way to ensure production output and avoid costly and time delaying stoppages. Further, when the body plate 302 is returned to the electromagnetic area 108 after dosed with the dosing material, the operator may manually inspect the body plate 302 from the operator stations 106. The manual inspection provides a screening in addition to the inspection by the capsule inspection station 122. The combination of manual and automated inspection of the body plates 302 limits risk of contamination on the electromagnetic area 108 and the non-electromagnetic area 110. Further, the capsule-filling manufacturing unit provides for individual tracking of body plate 302 and the corresponding magnetic mover 112. After dosing the capsule bodies 404 with the dosing materials, the body plate 302 may be returned to the non-electromagnetic area 110 by the magnetic mover 112. The machine management system provided in the capsule-filling manufacturing unit may identify the body plate 302 through a scanning technique. Further, by identifying the body plate 302, the machine management system may also track dosing of any of the capsule bodies 404 by mapping the capsule bodies 404 with the respective magnetic mover 112. The identification of the body plate 302 and the corresponding magnetic mover 112 enables the machine management system to test and track compliance of each body plate 302 returned from the capsule dosing station to the predefined production recipes. Moreover, the individual tracking of the body plate 302 enables for processing multiple products simultaneously and allows for variable dosing in the capsule dosing stations.

Further, the capsule-filling manufacturing unit is capable of dynamically moving the capsules through the production process that allows for modular scaling of production by adding or removing production stations as desired. The modularity allows to increase stations with slow indexing times, thereby optimizing production cycle times and significant improvement in production output. The system provides for the ability to infeed and outfeed between production lines and sub production areas may be carried out with smart and efficient scheduling. Furthermore, the system provides for the ability to dynamically route product in the manufacturing process according to real time availability of production stations thereby maximizing production output and utilization. The system further provides for the ability to stack products in production process dynamically within the production area, thereby ensuring quantities of buffer items which ensure there is no production waiting times and maximizing efficiency. The system further provides for the ability to stack products in progress in the event of stoppages, cleaning or maintenance without stopping upstream processes. Furthermore, the system provides for the ability to change out batches quickly by only replacing selected modular stations.

While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.
, Claims:1. A capsule-filling manufacturing unit, comprising:
a capsule handling system (100) comprising:
a plurality of stations adapted to perform a plurality of operations on at least one capsule loaded in a plate assembly (403), each station located in a non-electromagnetic area (110) of the capsule-handling system (100), wherein:
a capsule orientation and loading station (118) from among the plurality of stations is adapted to orientate and load capsules in the plate assembly (403).
a cap plate handling station (120), from among the plurality of stations is adapted to separate a cap plate (401) from a body plate (302) of the plate assembly (403) separating a capsule cap (402) from a capsule body (404), the cap plate (401) is adapted to hold the capsule cap (402) therein, the body plate (302) is adapted to hold the capsule body (404) and having a channel (406) defined underneath the capsule body (404); and
an electromagnetic mover system located outside the non-electromagnetic area (110) and having at least one magnetic mover (112), at least one electromagnetic area (108), and at least one handling mechanism,
wherein the non-electromagnetic area (110) is adapted to provide a bottom passage (128) to access the body plate (302) to perform the plurality of operations in at least one of the plurality of stations, the at least one handling mechanism is adapted to transfer the body plate (302) from the non-electromagnetic area (110) to the electromagnetic area (108).

2. The capsule-filling manufacturing unit according to claim 1, wherein the capsule handling system (100) further comprises support structures and gantries provided in the plurality of stations, the support structures and gantries are adapted to provide structural support and resist a lateral and vertical movement of one of the plate assembly (403) and the body plate (302) during performing the plurality of operations.

3. The capsule-filling manufacturing unit according to claim 1, comprises:
a first handling mechanism (102) adapted to transfer the plate assembly (403) from a capsule ejection station (126) to the capsule orientation and loading station (118), from among the plurality of stations to perform a first set of operations, wherein the first set of operations includes a capsule loading operation, a capsule detection operation, a capsule separation operation, a cap plate (401) transfer operation and a cap plate (401) storing operation.

4. The capsule-filling manufacturing unit according to claim 1, comprises:
a second handling mechanism (104) adapted to transfer the body plate (302) from the non-electromagnetic area (110) to one of the magnetic mover (112) in the electromagnetic area (108) after completion of the first set of operations and re-transfer the body plate (302) from the electromagnetic area (108) to the non-electromagnetic area (110) to perform a second set of operations, wherein the second set of operations includes a capsule body (404) inspection operation, a capsule recapping operation, a capsule weighing operation, and a capsule ejection operation.

5. The capsule-filling manufacturing unit according to claim 1, wherein:
the non-electromagnetic area (110) comprises a first plate mover (114) and a second plate mover (116), the first plate mover (114) and the second plate mover (116) are disposed parallel to each other across the plurality of stations,
wherein the first plate mover (114) and the second plate mover (116) are configured to aid the movement of one of the plate assembly (403) and the body plate (302).


6. The capsule-filling manufacturing unit according to claim 1, wherein a first alignment mechanism is adapted to align the body plate (302) with the cap plate (401) and comprises:
more than one profiled formation of a combination of raised or recessed formations on the body plate (302), wherein each formation is adapted to be received within or into a corresponding opposite formation provided on the cap plate (401) such that the body plate (302) is aligned with the cap plate (401).

7. The capsule-filling manufacturing unit according to claim 1, wherein a second the alignment mechanism is adapted to align the magnetic mover (112) with the body plate (302) and comprises:
more than one profiled formation of a combination of raised or recessed formations located on a top surface of the magnetic mover (112), wherein each formation is adapted to be received within a corresponding opposite formation provided on the body plate (302) such that the magnetic mover (112) is aligned with the body plate (302).

8. The capsule-filling manufacturing unit according to claim 1, wherein the bottom passage (128) is defined below the plate assembly (403) or the body plate (302) in the first plate mover or second plate mover (114) such that a plurality of recesses for holding a plurality of capsule bodies in the body plate (302) is accessible via the channel (406).

9. The capsule-filling manufacturing unit according to any of the preceding claims, wherein:
the plate assembly (403) is adapted to be moved over the first plate mover (114) to the capsule orientation and loading station (118) from among the plurality of stations,
wherein, at the capsule orientation and loading station (118), the plurality of capsules are dispensed in the plate assembly (403) such that the capsule cap (402) is located within the cap plate (401) and the capsule body (404) is located in the body plate (302),
wherein a back pressure inside each channel (406) of the body plate (302) is released into the bottom passage (128) below the plate assembly (403) via an open end of the channel (406) in the body plate (302) when each channel (406) receives the capsule body (404).

10. The capsule-filling manufacturing unit according to claim 9, wherein a vacuum device (202) having a plurality of ports located within the bottom passage (128) is adapted to be in connection with the body plate (302) from the bottom passage (128) via the open ends of the channel (406) in the body plate (302) and a vacuum is applied via the plurality of ports by the vacuum device (202) to each channel (406) of the body plate (302) to guide the capsules into the plurality of recesses of the respective cap plate (401) and the body plate (302).


11. The capsule-filling manufacturing unit according to any of the preceding claims, wherein:
the capsule body detection station from among the plurality of stations is adapted to detect the presence of capsules in the plate assembly (403);
wherein the vacuum device (202) located within the bottom passage (128) is adapted to be in connection with the body plate (302) from the bottom passage (128) via the open ends of the channel (406) in the body plate (302) and the vacuum is applied via the plurality of ports by the vacuum device (202) to each channel (406) of the body plate (302) to detect the presence of the capsules in the plate assembly (403).

12. The capsule-filling manufacturing unit according to any of the preceding claims, wherein:
the plate assembly (403) is adapted to be moved over the first plate mover (114) to the cap plate handling station (120) from among the plurality of stations,
wherein, at the cap plate handling station (120), the cap plate (401) is adapted to be lifted by a gripper (602) in an upward direction with respect to the body plate (302) during a capsule separation operation.


13. The capsule-filling manufacturing unit according to claim 12, wherein the vacuum device (202) is adapted to apply a downward force in each channel (406) of the body plate (302) to pull or hold the capsule body (404) from the bottom passage (128) during the capsule separation operation.


14. The capsule-filling manufacturing unit according to claim 12, wherein in the cap plate handling station (120), the separated cap plates (401) are stacked and stored in a cassette arrangement such that any one of the cap plate (401) is recoupled with any one of the body plate (302) during the capsule recapping operation.

15. The capsule-filling manufacturing unit according to any of the preceding claims, wherein:
preceding to transferring the body plate (302) to or from the non-electromagnetic area (110), the body plate (302) the capsule body detection station from among the plurality of stations, is adapted to detect the presence of capsule body 404 in the body plate 302;
wherein in the capsule body detection station, the vacuum device (202) or an optical sensing device (204) is configured to detect the plurality of recesses in the body plate (302) is fully populated with the capsule bodies.

16. The capsule-filling manufacturing unit according to claim 1, wherein the non-electromagnetic area (110) is provided with an operator station (106) for manual intervention and adapted to allow performing a corrective action by an operator preceding to transferring the body plate (302) to the electromagnetic area (108).

17. The capsule-filling manufacturing unit according to any of the preceding claims, wherein the magnetic mover (112) is adapted to transfer the body plate (302) to one or more capsule dosing stations to fill the capsule body (404) with one or more dosing materials.

18. The capsule-filling manufacturing unit according to any of the preceding claims, wherein the second handling mechanism (104) is adapted to transfer the body plate (302) from the magnetic mover (112) located in the electromagnetic area (108) onto the second plate mover (116) in the non-electromagnetic area (110), wherein the capsule body (404) held in the body plate (302) is dosed with one or more dosing materials.

19. The capsule-filling manufacturing unit according to any of the preceding claims, wherein:
the body plate (302) is adapted to be moved over the second plate mover (116) to the capsule inspection station (122),
wherein, at the capsule inspection station (122), the body plate (302) is monitored by an optical sensing device (204) to detect defects in capsule bodies held by the body plate (302), the optical sensing device (204) is adapted to monitor the body plate (302) through the bottom passage (128) for a bottom inspection and from a top portion of the body plate (302) for a top inspection.

20. The capsule-filling manufacturing unit according to any of the preceding claims, wherein:
the body plate (302) is adapted to be moved over the second plate mover (116) to the capsule weighing station (124),
wherein, at the capsule weighing station (124), the capsule bodies (404) are weighed via a load sensor provided in the bottom passage (128) below the plate assembly (403), the load sensor is adapted to access each of the capsule bodies (404) in the body plate (302) via the channel (406) in the body plate (302),
wherein each of the capsule bodies (404) in the body plate (302) is individually detected for target weights in the capsule weighing station (124) to ensure compliance with a predefined recipe.

21. The capsule-filling manufacturing unit according to any of the preceding claims, wherein:
the body plate (302) is adapted to be moved over the second plate mover (116) to the cap plate handling station (120) from among the plurality of stations to perform the capsule recapping operation,
wherein, at the cap plate handling station (120), the separated cap plates (401) are adapted to be removed from the cassette arrangement and retained on the body plate (302) by the gripper (602) forming the plate assembly (403),
wherein the plate assembly (403) is aligned with a plurality of recapping pins (802) in the bottom passage (128) and adapted to apply an upward force on each capsule body (404) in the body plate (302), and the gripper (602) plate is adapted to resist the upward force, such that the capsule cap (402) and the capsule body (404) are recapped to form the capsule.

22. The capsule-filling manufacturing unit according to claim 21, wherein the plurality of recapping pins (802) is adapted to deliver a predefined amount of the upward force applied to the capsule bodies (404) and the gripper (602) plate is adapted to resist the upward force to enable attachment of the capsule cap (402) with the capsule body (404), wherein the predefined amount of the upward force applied by the plurality of recapping pins (802) is at least 25 newtons.

23. The capsule-filling manufacturing unit according to any of the preceding claims, wherein:
the plate assembly (403) is adapted to be moved over the second plate mover (116) to the capsule ejection station (126) from among the plurality of stations,
wherein the capsule ejection station (126) is adapted to selectively actuate ejection pins to eject capsules identified as non-defective or compliant from the plate assembly (403) based on the detection from one of the capsule inspection station (122) or the capsule weighing station (124), a plurality of ejection pins is actuated to apply an upward force on each capsule body (404) such that the identified non-defective or compliant capsule is ejected from the plate assembly (403) into production bins.

24. The capsule-filling manufacturing unit according to claim 23, wherein:
wherein the capsule ejection station (126) is adapted to selectively actuate ejection pins to eject capsules identified as defective or non-compliant from the plate assembly (306) based on the detection from one of the capsule inspection station (122), the capsule body detection station or the capsule weighing station (124), the identified defective or non-compliant capsules are ejected into a waste bin. prior to the ejection of compliant capsules into production bins.

25. The capsule-filling manufacturing unit according to any of the preceding claims, wherein a machine management system is configured to:
receiving an input indicative of an identification of the body plate (302) from the second handling mechanism (104); and
track the body plate (302) and corresponding magnetic mover (112), wherein the magnetic mover (112) and the body plate (302) are directed towards the one or more capsule dosing stations to dose the capsule bodies (404) based on the predefined recipe.

26. The capsule-filling manufacturing unit according to any of the preceding claims, wherein upon identifying the body plate (302) returning to the second plate mover (116), the machine management system is configured to:
compare the weight of the capsule bodies (404) identified by the capsule weighing station (124) with the target weight of the predefined recipe; and
validate the weight identified by the capsule weighing station (124) for production compliance.

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