Melt Bucket

Melt Bucket for Capsule Production Equipment
As a core pre-processing unit in hard capsule manufacturing lines, Melt Bucket is engineered to deliver precise, efficient, and hygienic dissolution of capsule shell materials-laying the foundation for consistent capsule quality, shape, and performance. Whether processing traditional gelatin or advanced plant-based polymers (e.g., HPMC, pullulan, carrageenan), our customized gel melting solutions integrate cutting-edge thermal control, homogenization, and automation technologies to meet the rigorous demands of pharmaceutical, nutraceutical, and functional food industries.

Core Functions & Operational Principles
Melt Bucket serves as the critical link between raw material handling and capsule formation, executing three key objectives:
Controlled Dissolution: Converts solid raw materials into homogeneous, bubble-free gel solutions through precise temperature regulation and gentle mixing. This avoids material degradation (e.g., protein denaturation in gelatin, polymer chain breakage in plant-based materials) while ensuring full hydration of ingredients.
Homogenization & Degassing: Eliminates agglomerates, air bubbles, and impurities via high-shear mixing and vacuum degassing systems. The result is a smooth, uniform gel with consistent viscosity-critical for preventing capsule defects such as uneven walls, pinholes, or brittleness.
Stabilized Storage: Maintains the gel solution at a constant temperature in a closed, sterile environment before transfer to the capsule forming machine. This prevents gel solidification, viscosity fluctuations, or microbial contamination during production.

Key Technical Features & Innovations
1. Precision Temperature Control System
Equipped with dual-layer jacketed design and PID (Proportional-Integral-Derivative) temperature control, achieving ±0.5°C temperature accuracy. This ensures optimal dissolution conditions for different materials: e.g., 50–55°C for gelatin, 60–65°C for HPMC, and 55–60°C for pullulan.
Insulated jacket minimizes heat loss, reducing energy consumption while maintaining stable process conditions-ideal for long-duration production runs.
2. Hygienic & Durable Construction
Crafted from food-grade 316L stainless steel (contact surfaces) and 304 stainless steel (non-contact parts), complying with GMP, FDA, and EU CE standards. The smooth, polished inner wall (Ra ≤ 0.8μm) prevents material adhesion and facilitates thorough cleaning (CIP/SIP compatible).
Sealed design with food-grade silicone gaskets and dust-proof covers prevents cross-contamination, ensuring gel purity for pharmaceutical-grade applications.
3. Efficient Mixing & Degassing Mechanisms
Variable-frequency speed control (50–300 RPM) for the agitator, allowing adjustment of mixing intensity based on material properties. The spiral impeller design ensures gentle yet thorough blending, avoiding shear-induced damage to sensitive plant-based polymers.
Integrated vacuum degassing system (vacuum degree: -0.06 to -0.09 MPa) removes air bubbles in real time, reducing gel porosity and improving capsule transparency and mechanical strength.
4. Intelligent Automation & Customization
PLC touchscreen control system enables one-click operation, parameter storage (up to 50+ recipes for different materials/capsule types), and real-time monitoring of temperature, viscosity, and mixing speed. Remote control and data logging are available for smart factory integration.
Customizable tank volumes (50L–5000L) to match production capacities (10,000–1,000,000 capsules/hour). Optional add-ons include viscosity sensors, automatic feeding systems, and CIP (Clean-in-Place) modules for enhanced efficiency.

Hot Tags: melt bucket, China melt bucket manufacturers, suppliers, factory