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PharmaTech Engineering Launches Next-Gen Equipment, Slashing Powder Waste for Global Drug & Supplement Makers□ Journalist: Li Mei□ Date: October 22, 2025
For pharmaceutical and health supplement manufacturers, powder loss during capsule filling has long been a costly headache. “We used to lose 8–12% of herbal powder every month—enough to make 50,000 extra capsules,” says Zhang Wei, production director at Huaxia Bio-Pharma, a leading Chinese herbal supplement firm. “That’s $15,000 in raw material waste alone, not counting the time spent cleaning leaked powder.”
This pain is industry-wide. A 2025 report by the Global Pharmaceutical Manufacturing Association (GPMA) shows that traditional automatic capsule filling machines cause an average 5–15% powder loss, leading to $2.3 billion in annual raw material waste for global drug makers.
Now, this issue has a solution. On October 20, PharmaTech Engineering, a specialist in pharmaceutical equipment, officially launched its new-generation Automatic Capsule Filling Machine (Model PT-CF800). After 6 months of on-site testing at 12 factories across Asia and Europe, the equipment has achieved a breakthrough: powder loss as low as 1%, far below the industry average.
What makes the PT-CF800 stand out? The machine integrates three innovative technologies to eliminate powder leakage at every step of the filling process.
Traditional machines rely on single-point clamping, which often leaves gaps between capsule bodies and caps—causing powder to leak during transfer. The PT-CF800 uses a dual-seal design:
A silicone ring clamps the capsule’s middle section to prevent horizontal leakage.
A vacuum suction cup secures the capsule cap, ensuring no powder escapes from the top.
“In our tests, this system reduced leakage from the capsule joint by 92%,” explains Chen Hao, chief engineer at PharmaTech.
Even small deviations in filling volume can lead to overfilling (wasting powder) or underfilling (needing rework). The PT-CF800 adds a high-precision weight sensor:
After each capsule is filled, the sensor checks its weight in 0.1 seconds.
If the weight is outside the set range (e.g., ±2mg), the machine automatically adjusts the filling pump—avoiding both waste and non-compliant products.
Powder flying during filling is another major source of waste. The PT-CF800’s powder chamber uses negative pressure (50Pa below atmospheric pressure):
Floating powder is sucked back into the chamber instead of spreading into the air.
This not only cuts waste but also keeps the workshop clean, helping factories meet GMP (Good Manufacturing Practice) standards.
The PT-CF800’s performance has already won over early adopters. Huaxia Bio-Pharma, which started testing the machine in April 2025, has seen dramatic results.
“Before, we used two traditional machines to produce 200,000 herbal capsules daily, with 10% powder loss,” Zhang Wei says. “After switching to the PT-CF800, we only need one machine to hit the same output, and powder loss dropped to 0.8%.”
The numbers speak for themselves:
Monthly raw material waste reduced from $15,000 to $1,200.
6-month total savings: $180,000.
Labor costs cut by 50% (fewer machines mean fewer operators and less cleaning time).
Similar results were seen at EuroHerb, a German supplement maker. “Our magnesium capsule production used to have 7% powder loss,” says EuroHerb’s operations manager, Thomas Müller. “With the PT-CF800, it’s down to 1.2%—and we no longer need to hire extra staff to clean leaked powder.”
The launch of the PT-CF800 is not just a win for cost savings—it also aligns with the global push for sustainable pharmaceutical manufacturing.
“Raw materials for drugs (especially biologics and rare herbal extracts) are often expensive and resource-intensive to produce,” says Wang Lin, a senior analyst at GPMA. “Cutting powder loss from 10% to 1% means less raw material extraction, lower energy use for production, and fewer carbon emissions. This machine is a game-changer for green pharma.”
For PharmaTech, the next step is to expand access to the technology. The company announced that it will offer free on-site demos of the PT-CF800 for the next 3 months, along with a 2-year warranty (covering all core parts) and free technical training for operators.
“We want every drug maker to stop wasting money on leaked powder,” says Liu Jian, CEO of PharmaTech. “The PT-CF800 isn’t just an equipment upgrade—it’s a way to make pharmaceutical production more efficient, cost-effective, and sustainable.”
PharmaTech plans to showcase the PT-CF800 at the 2025 International Pharmaceutical Machinery Exhibition (CPhI Worldwide) in Frankfurt next month. The company also revealed that it is developing a smaller version (Model PT-CF300) for small and medium-sized factories, which will launch in Q1 2026 with the same 1% powder loss capability.
For drug and supplement manufacturers struggling with powder waste, the message is clear: the era of high-loss capsule filling is over. With the new Automatic Capsule Filling Machine, 1% powder loss is now the industry standard.
To learn more about the PT-CF800 or book a free demo, visit PharmaTech’s official website or contact its sales team at sales@pharmatechequip.com.
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