| How to maintain the large pill shell removal machine |
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| 2026-7-23 publish |
Complete maintenance plan for large pill shell pressing machine (suitable for GMP management of pharmaceutical factories, divided into four levels of maintenance: daily, weekly, monthly, and annual)
Function of the shell-sealing machine: It automatically aligns and presses the upper and lower plastic shells containing pills together. It is a supporting equipment before the wax dipping machine. Faults will directly cause empty shells, poor sealing, shell explosion, and batch defects. The maintenance focuses on six modules: material handling track, pressing mechanism, pneumatic components, conveying and positioning, electrical sensing, and mold tooling.
1. Daily maintenance (must be done after each shift shutdown, 10-15 minutes)
1. Whole machine cleaning and disinfection (strictly required in pharmaceutical production)
Cut off the power supply, close the gas source, wait for the moving mechanism to completely stop. Wipe the hopper, dividing chute, guide slide rail, pressing head, and limit workpiece all with a dust-free cloth and 75% medical alcohol; clean scattered powder, broken plastic shell debris, dust, and the track without adhered medicine scale.
Clean the equipment frame, external protective cover, and tabletop, do not allow powder accumulation and blockage.
Take the receiving tray off, rinse and dry, strictly prohibit assembling with water.
Do not directly spray water on the machine body, cylinder, or electrical control box, only wet wiping is allowed.
2. Simple inspection of the air circuit
Check the air compressor three-piece assembly: the water separator discharges water daily, the oil mist absorber maintains the standard level of the oil level, the air source pressure is constant at 0.4-0.6 MPa.
Visualize that all air pipe joints have no leakage, white frost, or loosening; wipe the surface of the cylinder piston rod clean, no powder adheres.
Test the actions of each pushing cylinder and pressing cylinder without abnormal noise or crawling and jamming.
3. Appearance inspection of running components
Check for any scratches, deformation, or material adhesion on the pressing mold head and positioning groove, and whether the plastic shell is pressed unilaterally.
Clean the surface of the photoelectric level sensor of the sensor, avoid missing materials and blockage not triggering alarms.
Emergency stop switch, safety protection door rebound, and trigger sensitivity and effectiveness.
4. Running conclusion
Run the machine without load for 2-3 cycles, confirm smooth operation without abnormalities, then close the gas source and main power supply.
2. Weekly maintenance (uniform maintenance during shutdown each week, 30 minutes)
Lubrication of transmission and sliding parts
Add food-grade colorless high-temperature lubricating grease to the guide block, linear bearing, pin, cam, oscillating connecting rod; only a small amount is applied, the excess grease is wiped clean, and prevent grease from dripping and polluting pills and plastic shells. Add appropriate special chain oil to the chain structure.
Key point: ordinary industrial lubricants are strictly prohibited in pill production, as it will cause drug contamination and non-compliance.
Fine cleaning of molds and pressing heads
Remove the upper and lower shell-sealing molds, soak in alcohol to remove embedded powder in the gaps; check the wear of the mold cavity, chamfer, and burrs, burrs will crack the plastic ball shell, slight burrs can be ground and repaired with an oilstone.
Deep inspection of the air circuit
Check the sealing ring of each cylinder for any trace leakage; clean the surface of the electromagnetic valve body, and the connection terminals are free of dust and moisture.
Dust-proof and moisture-proof of the electrical control box
After power off, use dry compressed air to blow away dust and drug fog inside the electrical control box, keep the air intake ports unobstructed; in a humid workshop environment, a desiccant can be placed in the electrical control box.
Test the protection functions of blocking shells, missing pills, and no shells, ensure that the equipment automatically stops and alarms when the material is jammed.
3. Monthly maintenance (monthly comprehensive inspection)
Comprehensive tightening of mechanical fasteners
Recheck and tighten all screws of the frame, mold base, cylinder fixing seat, pressing assembly, and material trough support, as the equipment is prone to loosen due to long-term vibration, causing inconsistent depth of pressing and a large number of loose shell defective products.
Detection of wear of transmission components
Check for cracks, aging, and slackness of synchronous belts and conveyor belts, adjust the tension of the tension wheel in time; replace the spring tightening parts that are fatigued and soft directly.
Calibration and cleaning of sensing elements
Re-calibrate the photoelectric sensors and proximity switches for the sensing distance; clean the lens stains to avoid false signals causing the equipment to act erratically and fail to seal properly.
Maintenance of cylinders and electromagnetic valves
Check for scratches on the piston rod of the pressing cylinder, clean the impurities on the electromagnetic valve core; replace the sealing ring of the leaking seal ring in a complete set.
Check the grounding circuit of the entire machine, ensure a firm grounding, and prevent static electricity breakdown of components and static adsorption of dust. IV. Annual / Quarterly Major Overhaul and Maintenance (Deep overhaul every 6 months)
Fully disassemble the transmission assembly: clean the bearings, cams, and rotating shafts, replace old lubricating grease, and replace the bearings with excessive wear directly.
Perform flaw detection on the entire set of clamping molds, replace deformed or severely worn molds immediately to ensure the shell clamping is tight and seamless (too large gaps will inevitably lead to leakage and air leakage after dipping wax later).
Replace aging rubber parts such as solenoid valves, air pipes, and silicone buffer pads in batches. Rubber parts are prone to hardening and cracking due to long-term exposure to powder.
Perform insulation tests for the motor, check for aging wiring, replace aging cables; back up the PLC operation parameters of the equipment.
Carry out stainless steel passivation maintenance for the entire machine, remove rust and scale from the contact surfaces; conduct long-term no-load operation of the entire equipment, record and archive all operation parameters.
V. List of Frequent Replacement Parts (Daily stock, reducing downtime)
Silicone buffer pressure heads, O-ring seals, suction cups, photoelectric switches, transmission belts, cylinder oil seals, springs, guide sliders.
VI. Usage and Maintenance Precautions (Key points to avoid common mistakes)
During equipment operation, do not reach in to clean blockages or wipe the molds. Press the emergency stop button and cut off the power supply for operation.
The lubricating grease must be food-grade; do not use black industrial butter. Once it gets into the batch of pills, they will all be scrapped.
Do not forcibly increase the air pressure to compress the plastic shell. Excessive air pressure will cause the plastic shell to burst in batches. The standard pressure must be strictly controlled within the process range.
After alcohol wiping, dry it thoroughly before starting the production. Residual water vapor will cause electrical short circuits and rusting inside the cylinder.
Do not randomly modify the factory-set clamping stroke and down-pressure depth parameters of the equipment. Any modifications must be registered in the ledger.
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