Aftermarket Products for Encapsulation Machines · 2021. 2. 5. · Aftermarket Products for...

Aftermarket Products for Encapsulation Machines.

Subject to alteration | July 2020 | PA-PCS/PRM-US

You will find your Service partner at:WWW.SYNTEGON.COM/SERVICES

Aftermarket Products for Encapsulation Machines.

Subject to alteration | December 2020 | PA-PCS/PRM-US


TABLE OF CONTENTSIntroduction ...........................................................................................................................................4Contact list ............................................................................................................................................5

GENERAL E-Portal ................................................................................................................................6 Stock Optimization ...............................................................................................................8 Preventive Maintenance Agreements ..................................................................................9

PREVENTIVE MAINTENANCE KITS Preventive Maintenance Kits for GKF & DMW Capsule Fillers .........................................10 Preventive Maintenance Kits for KKE Checkweighers ......................................................12

UPGRADE KITS 21 CFR Part 11 Compliance Upgrade Kit ..........................................................................14 Bronze to Aluminum Guide Ring Upgrade Kit ...................................................................15 Cleaning Station Upgrade Kit ............................................................................................16 GKF 1500 Controls Upgrade Kit ........................................................................................17 GKF 2000 Controls Upgrade .............................................................................................18 Dust Removal Upgrade Kit ................................................................................................19 Ejection Shaft Upgrade ......................................................................................................20 ELAU Motion Control .........................................................................................................21 ENT 6 Eliminator Kit ..........................................................................................................22 GKF Capsylon 705 Powder Auger Upgrade Kit.................................................................23 Increased Capsule Output Upgrade Kit .............................................................................24 Non-Bosch to Bosch Machine Conversion Kit ...................................................................25 Powder Diverter Upgrade Kit .............................................................................................26 Powder Station Upgrade Kit ..............................................................................................27 Simplified Cleaning Station ................................................................................................28 Sticky Product Upgrade Kit ................................................................................................29 Tamping Shaft Bearing Seal Upgrade Kit ..........................................................................30 PRODUCT SPECIFIC PARTS Breakaway Style Closing Pins ...........................................................................................31 Cleaning/Ejection Station and Brushes .............................................................................32 Counter Closing Block .......................................................................................................33 Dosing Disk for GKF Capsule Fillers .................................................................................34



TABLE OF CONTENTSPRODUCT SPECIFIC PARTS con‘t. Plastic Sorting Blocks and Fingers .....................................................................................35 Plastic Wiper Block Shoe....................................................................................................36 Powder Augers ...................................................................................................................37 Powder Bowl Cone .............................................................................................................38 Tamping Pin Guide Rings ...................................................................................................39 Tamping Ring for Sticky Products ......................................................................................40

SPECIAL TOOLS Alignment Pins ....................................................................................................................41 Grease Applicator Tools .....................................................................................................42 Lower Segment Carrier Alignment Tool..............................................................................43 Rectifier Alignment Pins......................................................................................................44 Segment Turret Gearbox Alignment Tool ...........................................................................45 Sticky Product Package ......................................................................................................46 Transfer Station to Segment Turret Alignment Pins ...........................................................48 Upper Segment Carrier Alignment Tool..............................................................................49 Wear Gauge Sets ...............................................................................................................50

AUXILIARY DEVICES 9L Filtered Pre-Separator ...................................................................................................51 Capsule Polisher.................................................................................................................52 Dust Collection Systems .....................................................................................................53 Empty Capsule Conveyor ...................................................................................................55 Slug Tester .........................................................................................................................56

MACHINE HIGHLIGHTS All GKF’s .............................................................................................................................57 GKF 702 .............................................................................................................................58 GKF 1200, 1500 and DMW 1500, 2000 .............................................................................59 GKF 1400 ...........................................................................................................................60 GKF 2000, 2500 .................................................................................................................61 GKF 2500 ASB Series ........................................................................................................62 GKF 2600 ...........................................................................................................................63 GKF 3000 ...........................................................................................................................64 GKF Capsylon ....................................................................................................................65 KKE 1700............................................................................................................................66 KKE 2500............................................................................................................................67

Subject to alteration | June 2020 | PA-PCS/PRM-US


Syntegon Technology Services, LLC8700 Wyoming Avenue NorthMinneapolis, MN 55445-1836

Telephone: (763) 424-4700Fax: (763) 493-6137

Dear Customers:

We are pleased to present our latest catalog of Aftermarket Products for Encapsulation machines. The contents of this catalog are applicable to GKF, H&K and DMW encapsulators as well as the KKE capsule check-weighers as indicated. We offer Upgrade Kits, PM kits, Special Tools, and Replacement Kits for obsolete components for this equipment.

If you are looking for a solution that is not covered in this catalog, please contact us. In addition to our standard products, we offer customized solutions and execute customer-specific projects that suit your individual needs.

Our Service Products at a glance:

ʨ Spare Parts, Overhauls and Upgrades ʨ Change Parts, Product Testing and Optimization ʨ Training at Customer Site or Bosch Facilities ʨ Preventive Maintenance Kits ʨ Preventive Maintenance Agreements ʨ Validation and Calibration Services

We are committed to supporting our equipment over its entire lifetime. We have Service Technicians based around the world, including all regions of North America and Puerto Rico. Manufacturing and warehousing facilities in the USA and overseas expedite parts delivery and reduce your cost.

Please see the directory on the following page to contact us, or visit our web site at www.syntegon.com.

Sincerely,Syntegon Technology Services, LLC

Service Contacts.

Subject to alteration | January 2021 | PA-PCS/PRM-US


Mailing Address: Syntegon Technology Services, LLCNorth American Pharmaceutical Operations8700 Wyoming Avenue NorthMinneapolis, MN 55445-1836 Phone: (763) 424-4700Fax: (763) 493-6137

www.syntegon.com

Contacts:

Location Name Phone EmailAfter Market SalesWestern US & PR Dave Bethel 612-868-7686 [email protected] US & Canada Mark Moulton 613-802-8746 [email protected] PartsEastern US & California Kristina Norton 763-493-6116 [email protected] US, Canada & PR Mark Gustafson 763-493-6140 [email protected] US Kim Brown 763-493-6796 [email protected] ServiceField Service Manager Ben Seifert 763-493-6729 [email protected] Service Coordinator Thomas O’Gara 763-493-6718 [email protected] Hours Emergencies 1-800-947-1166

E-Portal.SPARE PARTS ARE JUST A CLICK AWAY.

E-Portal: Online information and ordering The E-Portal is the online information and ordering platform from Syntegon Technology. The portal contains customer as well as machine specific spare parts data, allowing transparent flow of information and thus simplifying the request and order processes and increasing the efficiency of your spare parts logistics.

If required, all members of staff involved in ordering spare parts can be provided with a login to access the portal. Detailed spare parts information with price and availability as well as direct ordering facilities are available around the clock and in all commonly spoken languages.

You can access the E-Portal via the After-Sales Services section of our website www.syntegon.com or directly via www.syntegon.com/ePortal. Here you can use the login screen to log in.

Additional functionsUsing the Open Catalog Interface (OCI) product information may be transferred to your internal purchasing catalog or ERP system. This allows you to submit offer and order requests via your company’s own internal system while being able to use the E-Portal information. The E-Portal also offers interfaces with Coupa and Ariba.

In the Corporate Portal several location-specific E-Portals may be combined. This combination may be for the benefit of a corporation, a purchasing organization, etc. It enables an E-Portal user to manage offer and order processes for several locations while having access to relevant information on all spare parts.

Your benefits

ʨ Online information and ordering around the clock ʨ Detailed spare parts information ʨ Customer specific technical document management ʨ Optimization of logistics and storage costs ʨ Stationary and mobile applications

Homepage: Detailed product search and information.

Up-to-date information on price, availability and delivery time can be accessed online at any time. Detailed product information and the option to track offers and orders ensure transparency. Alm Vita also appreciates these benefits*.

Order and Planning Tool.Search and informSearching for spare parts is fast and easy. Up-to-date informa-tion on prices, availability and products is available at any time.

Plan and orderSpare parts may be marked on a memo for orders or main-tenance projects. Your order is processed via a basket. If required, baskets may also be transferred to your internal purchasing catalog system.

Request and trackYou also have the option to request a written quotation for the items in your shopping basket. Orders as well as any quotes can be found by selecting the E-Service tab. All orders and quotes within the last 24 months can be viewed sorted down to individual item level.

Download up-to-date informationUnder the Info Service tab you can find customer and machine specific information, e.g. on available upgrade kits or parts superseding discontinued components.

Mobile E-PortalThis new app allows for access to all E-Portal functionalities with your mobile devices, so you can create requests and orders directly from the machine. As an alternative, you can compile memos and forward them to other users or depart-ments for further processing.

By activating the NFC tag on your device, machines are recognized automatically. The corresponding machine specific documentation is available on site and in real time.

Be one step ahead. The E-Portal in use at Alm Vita*

Alm Vita specializes in herbal vitamin supplements. They follow the highest quality standards for processing of selected herbs. The seasonal periods of peak production mean that stringent planning for Alm Vita is essential. “The E-Portal from Syntegon Technology gives us optimal support” reports the Production Manager. “It supplies us with all important spare parts information on prices, availability and delivery time. This enables us to plan and carry out very precisely the revision and maintenance for our packaging machinery.” Critical parts can be identified by a mouse click and ordered to stock in preparation for an emergency. Alm Vita has seen a remarkable improve-ment in spare parts logistics.

For the purchasing department the online platform elimi-nates the time-consuming search through numerous spare parts catalogs. Thanks to technical data and photo-graphs, the required parts can be found fast and easily.The process for requesting quotes and orders has been

simplified. If the production workers notice an irregularity with a machine outside normal working hours, they can mark parts on a memo in the E-Portal and the purchasing department will order them from Syntegon the very next day.

Around the clock, the E-Portal provides Alm Vita with customized spare parts information. The transparent flow of information allows for rapid decision-making. This has enabled Alm Vita to streamline and improve their logistics process considerably. Presently, Alm Vita plans to connect the E-Portal with its internal ERP system. “This step appears to be the logical consequence of the strength of our past experience. We see a further increase in the efficiency of our spare parts logistics and procure-ment” explains the Purchasing Manager of the innovative manufacturer of vitamin supplements.

* company name changed

PA-PCS/MKT, PA-FCS/PRM, 03.2020, subject to alterations

You will find your local partner at:WWW.SYNTEGON.COM/SERVICES

Stock Optimization.INCREASED PROFITABILITY THROUGH IMPROVED SPARE PARTS MANAGEMENT.

Analyze to optimizeThe biggest challenge in spare parts management is achieving high availability with minimal stock. Improving your overall spare parts management requires detailed knowledge about your exact spare parts consumption and delivery times. With our consumption based Stock Optimization concept, we can provide you with detailed information specific to your spare parts profile. By combining an analysis of your individual parts consumption with up-to-date information on our Syntegon stock levels and delivery times, we will support you to improve procurement planning, maximize spare parts availability and increase the profitability of your stock investment.

By optimizing your stock you can improve your spare parts availability and increase the profitability of your stock investment.

The tailored solution for your spare parts stock Using specially developed software, a team of dedicated Syntegon experts will generate a detailed spare parts profile by analyzing your previous consumption as documented in our system. The profile not only contains your offer and order history with order frequency, but also our supply information and delivery times for your spares. In addition, discontinued and obsolete parts are shown in this analysis, allowing long-term procurement planning. For more in depth analysis, we can include the spare parts data from your procurement sys-tem (e.g. your own part numbers) in the analysis. Our experts will prepare a structured report of the analysis results to dis-cuss with you in detail. We will identify potential improvements on both the supply and demand side, and work together with you to find a customized solution for the optimization of your spare parts management.

Your benefits

ʨ Increased cost effectiveness of your stock ʨ Optimized spare parts availability ʨ Improved procurement planning ʨ Detailed report of your spare parts profile ʨ Transparent information on our Syntegon stock

PA-PCS/MKT, PA-FCS/PRM, 03.2020, subject to alterationsYou will find your local partner at:WWW.SYNTEGON.COM/SERVICES

Preventive Maintenance Agreements.



Piece of mind and reliability through regular maintenance visits

What is a Preventive Maintenance Agreement?

A Preventive Maintenance Agreement (PMA) ensures that appropriate periodic maintenance activities are carried out at the right time. This does not replace the ongoing maintenance by your own staff but complements it with expert insight and ongoing knowledge transfer to plant mechanics and operators.

Whenever possible, the same service engineer(s) (based on your preference) are assigned to your agreement. We also provide support by phone or e-mail between visits with our Syntegon technical support team which provides quick access to Syntegon expertise.

A PMA is not a complex contract or a guarantee with an unclear promise; you sign up for an agreed-upon series of service visits over a period of time, and we do the rest. A PMA can be tailored to your specific needs and can be as open or as specific as desired.

* Please contact us at 763-424-4700 for specific discount rates

ʪ The right Preventive Maintenance measures at the right interval, executed by experts who are familiar with your equipment, your operation and your products

ʪ Planned/scheduled visits

ʪ Reliability and availability of your Syntegon equipment

ʪ Reduced downtime by preventing costly failures

ʪ Discount* on hourly rates and lower travel expenses (by booking travel early) guaranteed for the duration of the agreement

ʪ Discount on parts*

ʪ Summary report indicating completed tasks and recommended actions

ʪ One emergency visit at same discounted rate

Your benefits

Preventive Maintenance made easy.PM Kits for GKF and DMW capsule fillers

Minimize unplanned downtime with scheduled preventive maintenance

We have all been there: An entire packaging line is down for an hour because a small bearing deep inside a machine has failed just as an urgent shipment is scheduled to leave for the distribution center. This would not have happened, had the bearing been replaced during a scheduled downtime the previous weekend.

Preventive Maintenance has long been instituted in manufacturing plants around the world, but it comes with its own challenges. Which parts do you replace? How often do they need to be replaced?

This is where our PM Kits come in. Syntegon has drawn on its experience from seeing equipment in many different plants and circumstances, and has compiled a kit with parts that should be replaced at certain intervals. This takes the guesswork out of preventive maintenance, and eliminates time consuming ordering of individual small parts.

Standard approach, customized solutionWhen an order is received, Syntegon begins its review by comparing the standard list of parts for each machine type with the original bill of material of the specific machine being serviced. This ensures an efficient and standardized solution that is tailored to your needs.

PricingOn all standard PM Kits, Syntegon is granting a discount of typically 5% off the price of individual parts.

ʪ Preventive Maintenance without the guesswork. Know which parts to replace at which interval.

ʪ Minimize maintenance downtime by following a methodical, planned approach.

ʪ Typically 5% discount on kit orders compared to individual parts.

Your benefits



List of individual PM KitsUse the table provided below to reference the specific PM Kit for your machine.

Minor PM Kits Part Number Recommended Frequency ****Minor PM Kit for DMW 700, GKF 400 and GKF 700 PK_8111347823* Every 2,000 hours or annually,

whichever comes firstMinor PM Kit for GKF Capsylon 705 PK_8111388808*Minor PM Kit for GKF Capsylon 1505 PK_8111393055*Minor PM Kit for GKF Capsylon 3005 PK_8110405372*Minor PM Kit for GKF 2000 PK_8111350746*Minor PM Kit for GKF 2500 PK_8111356798*Minor PM Kit for GKF 2500 ASB 100% PK_8111359188*Minor PM Kit for GKF 1500 / DMW 1500 PK_8111347780**Minor PM Kit for GKF 1400 PK_8110401353*Minor PM Kit for GKF 1400L PK_8110405374*Minor PM Kit for DMW 2000 PK_8111381668**Major PM Kits Part Number Recommended Frequency ****Major PM Kit for GKF 700 PK_8111391524* Every 6,000 hours or three

years, whichever comes firstMajor PM Kit for GKF Capsylon 705 PK_8111388809*Major PM Kit for GKF Capsylon 1505 PK_8111393056*Major PM Kit for GKF Capsylon 3005 PK_8110405373*Major PM Kit for GKF 2000 (includes all parts of the minor kit) PK_8111350747*Major PM Kit for GKF 2500 (includes all parts of the minor kit) PK_8111356797*Major PM Kit for GKF 2500 ASB 100% (includes all parts of the minor kit) PK_8111359283*Major PM Kit for GKF 1500 / DMW 1500 PK_8111344970**Major PM Kit for GKF 1500 / DMW 1500 with plastic parts PK_8111393300**Major PM Kit for GKF 1400 (includes all parts of the minor kit) PK_8110401352*Major PM Kit for GKF 1400L (includes all parts of the minor kit) PK_8110405375*Major PM Kit for DMW 2000 PK_8111381669**Main Shaft Rebuild PM Kits Part Number Recommended Frequency ***Main shaft rebuild assembly PM Kit for GKF Capsylon 705 PK_8110405378* As needed based on your

machine maintenance scheduleMain shaft rebuild assembly PM Kit for GKF Capsylon 1505 PK_8110405376*Main shaft rebuild assembly PM Kit for GKF Capsylon 3005 PK_8110405377*Main shaft rebuild assembly PM Kit for GKF 2000 PK_8110405379*

Notes:Special tools are needed to install the kits on the GKF 2000 and GKF 2500. They are available under the number 8111352984.* Does not include cams, pellet/tablet feeding parts or any parts that are not part of a standard machine.** Does not include the bearings located in the yokes and main shaft or any parts that are not part of a standard machine.*** Assumes typical use. Depending on product type, environmental conditions, etc.**** Assumes typical use. Depending on product type, environmental conditions, etc.; the required interval may be longer or shorter.

Preventive Maintenance made easy.PM Kits for KKE checkweighers

Minimize unplanned downtime with scheduled preventive maintenance

We have all been there: An entire packaging line is down for an hour because a small bearing deep inside a machine has failed just as an urgent shipment is scheduled to leave for the distribution center. This would not have happened, had the bearing been replaced during a scheduled downtime the previous weekend.

Preventive Maintenance has long been instituted in manufacturing plants around the world, but it comes with its own challenges. Which parts do you replace? How often do they need to be replaced?

This is where our PM Kits come in. Syntegon has drawn on its experience from seeing equipment in many different plants and circumstances, and has compiled a kit with parts that should be replaced at certain intervals. This takes the guesswork out of preventive maintenance, and eliminates time consuming ordering of individual small parts.

Standard approach, customized solutionWhen an order is received, Syntegon begins its review by comparing the standard list of parts for each machine type with the original bill of material of the specific machine being serviced. This ensures an efficient and standardized solution that is tailored to your needs.

PricingOn all standard PM Kits, Syntegon is granting a discount of typically 5% off the price of individual parts.

ʪ Preventive Maintenance without the guesswork. Know which parts to replace at which interval.

ʪ Minimize maintenance downtime by following a methodical, planned approach.

ʪ Typically 5% discount on kit orders compared to individual parts.

Your benefits



List of individual PM KitsUse the table provided below to reference the specific PM Kit for your machine.

PM Kits Part Number Recommended Frequency *PM Kit for KKE 1500 PK_8111354035 Every 4,000 hours

PM Kit for KKE 2000 PK_8111354061 Every 4,000 hoursMajor PM KIt for KKE 1700 PK_8110405369 Every 6,000 hoursMinor PM Kit for KKE 1700 PK_8110405368 Every 2,000 hoursMajor PM Kit for KKE 2500 PK_8111359079 Every 6,000 hoursMinor PM Kit for KKE 2500 PK_8110400651 Every 2,000 hoursMajor PM Kit for KKE 3800 PK_8110405371 Every 6,000 hoursMinor PM Kit for KKE 3800 PK_8110405370 Every 2,000 hours

Notes:* Assumes typical use. Depending on product type, environmental conditions, etc., the required interval may be longer or shorter.

21 CFR Part 11 Compliance Upgrade Kit.

Subject to alteration | August 2020 | PA-PCS/PRM-US


ʨ 21 CFR Part 11 compliance is integrated in the machine controls, not a separate device

ʨ No change of functional SOP’s is required; only procedural SOP’s change

Your benefits

Upgrade your KKE 2500 checkweigher to be 21 CFR Part 11 Compliant

Figure 1 — 21 CFR part 11 compliant operator panel

Audit Trail ʨ All process, quality and product related entries and

modifications are recorded with date, time, action, user name

ʨ Entries can not be modified or deleted ʨ Security system to detect modified files

Report ʨ Printable / exportable ʨ Details are filterable

Electronic Signatures ʨ Not used ʨ Electronic records printed, prepared for hand

signatureAccess Protection ʨ No action without login with account and

password

ʨ Password security: alphanumeric, minimum length, “prohibited list”, automatic expiration, automatic logout, account lock after incorrect login attempts.

ʨ Configurable access groups for each user ʨ Logical user guidance, request for compulsion

entries

Applicable EquipmentKKE 2500 Check-weigher

Bronze to Aluminum Guide Ring Upgrade Kit.



Extend the life cycle of your machine with a new aluminum guide ring

DescriptionLoose tamping pins in the bronze guide ring may damage your machine and affect product quality. Avoid this situation by upgrading your machine from the outdated bronze guide ring to the new aluminum guide ring assembly.

Ordering informationKit with plastic parts: 8111343536Kit with standard parts: 8111343535

Applicable equipmentGKF 1200 & 1500

Cleaning Station Upgrade Kit.

Subject to alteration | September 2020 | PA-PCS/PRM-US


Sticky, dusty products cutting down your yields?

Syntegon offers a new Cleaning Station Upgrade Kit to instensify the segment cleaning ability of your GKF 2000/2500. Your

current plumbing and timing are modified to maximize the cleaning ability of your GKF 2000/2500.

Figure 1 — Cleaning Station Upgrade Kit

GKF 2000 and 2500 upgrade part number ʨ PK_8111338599

ʨ Longer cleaning pins allow both lower and upper segments to be thoroughly cleaned

ʨ Minimized capsule separation problems due to less product residue left on segments

ʨ Easy on-site installation ʨ Increased yields by increasing capsule

separation efficiency

Your benefits

GKF 1500 Controls Upgrade Kit.



Upgrade Specifics

ʨ Allen Bradley PLC with Ethernet communication, I/O Modules and Analog Module

ʨ Touchscreen Operator Interface Panel with a new enclosure offset from the existing cabinet ʨ New electrical cabinet backplane, fully assembled,

complete with new components as needed (transformer, circuit breakers, fuses/fuseholders, AC Drives)

ʨ Replacement of the existing cam box with a new encoder

ʨ New variable frequency drive motor and automated gearbox

ʨ New variable frequency drive auger motor for compatibility with new controls ʨ Remote jogging cable which allows slow advance

of machine

ʨ Supplemental operators manual and spare parts documentation for controls can help to ensure your control system is up to date and supportable for years to come.

Please contact us for a controls upgrade quote customized for your specific GKF or DMW model.

GKF 2000 Controls Upgrade.

Subject to alteration | November 2020 | PA-PCS/PRM-US


ʨ Elimination of all obsolete components in your control system

ʨ Increased reliability and improved troubleshooting

ʨ Remote support for reduced downtime ʨ US based control system ʨ Readily available off-the-shelf components ʨ OPC compatible ʨ Improved functionality ʨ Lower cost of ownership

Your benefitsSyntegon and our business partner IPR, Inc. offer Allen-Bradley control system upgrades including Allen-Bradley PLC, HMI and frequency drives for GKF 2000 capsule fillers. Increase your machine performance and decrease risk and downtime with this upgrade.

Dust Removal Upgrade Kit.



ʨ Designed for easy installation with only minor modifications to bowl cover

ʨ Connects to your existing dust collection system

ʨ Reduces airborne product ʨ Less product build-up on table top

Your benefits

GKF 2000 part numbers ʨ 8111349087 Complete Kit ʨ 8104234241 Ejection Chute ʨ 8104232625 Powder Station ʨ 8104232626 Powder Infeed ʨ 8104232627 Dust Extraction Chute

GKF 2500 part numbers ʨ 8111394987 Complete Kit ʨ 8104234241 Ejection Chute ʨ 8111395644 Powder Station ʨ 8104232626 Powder Infeed ʨ 8104232627 Dust Extraction Chute

Complete kit requires 150 m3/h of additional vacuum

Figure 1 — Complete Kit

Figure 2 — Ejection Chute

Figure 3 — Powder Station

Figure 5 — Dust Extraction Chute

Figure 4 — Powder Infeed

Our dust removal upgrade kit can help reduce the amount of dust created while running dusty products. Target specific areas on your machine or use the complete kit.

Ejection Shaft Upgrade.



ʨ Stabilizes ejection shaft drive for durability ʨ Reduces lower ejection shaft failure ʨ Reduces downtime ʨ Easy installation

Your benefits

Upgrade your older GKF Capsylon 1505 and 3005 to the latest ejection shaft assembly

Ejection Shaft Upgrade part number ʨ 8109608717 Please contact your Customer Support Representative at 763-424-4700 if you are unsure of your ejection shaft drive assembly design

ELAU Motion Control.



Discontinuation of ELAU Motion Control

ELAU has discontinued several motion control components. We recommend upgrading to the latest ELAU servo controller model to ensure that you have a replacement unit in the case of a failure.

This concerns the following series:

ʨ PMC-2 Controller, SB motors and accessories Repairs of defective components will be available until the end of 2015

ʨ PacDrive Controller MAX-4 including all options and accessories

Repairs of defective components will be available until the end of 2018

We will be happy to advise you on possible upgrades.ELAU PMC-2 ELAU MAX-4

ENT 6 Eliminator Kit.



ʨ Product level in bowl is monitored with a proximity sensor

ʨ Easy to install ʨ Replaces 230 volt AC or 24 volt DC systems ʨ For newer style aluminum guide ring only

Your benefits

Figure 1 — Eliminator Kit

Having trouble maintaining consistent bowl levels with your current ENT 6 powder level sensor?

Syntegon Technology Services offers a complete kit to replace your old ENT 6 and make powder level adjustments much simpler.

GKF 1500 part number ʨ PK_8111326826

GKF Capsylon 705 Powder Auger Upgrade.



ʨ Increased powder feed control ʨ Slinger disk included for free flowing

powders

ʨ Two piece auger shaft design eliminates using spacers to change slinger disk spacing

ʨ Easy installation ʨ Uses for existing large agitator

Your benefits

Improve powder feed control

Assembly Bill of MaterialsPart Number Description8109608219 Powder hopper tube8109608218 Feed auger8109600262 Upper adjustment shaft8109600263 Lower adjustment shaft8104222579 Slinger disk8108105772 Hexagon screw M6 x 208108129425 Dowel pin M6 x 308104234270 Adjustment screw M6 x 20

Replace the short feed auger design on your GKF Capsylon 705 capsule filler to this full length assembly. Change slinger disk spacing quickly and easily without removing lower tube and adding or removing spacers for free-flowing powders. It’s as simple as removing the powder hopper sight glass and changing the length of the auger shaft.

Assembly part number ʨ 8109600404

12 to 16 Bore Increased Capsule Output Upgrade Kit.



Enhance productivity and yield

GKF 1200, GKF 1500 and DMW 1500 upgrade kitPart Number DescriptionPK_8111398457 Aluminum to aluminumPK_8111344684 Bronze to aluminum

Need to increase production yields?Syntegon Technology Services offers a new and affordable way to increase the productivity and output of your existing GKF / DMW 12 bore capsule filling machine to 2,000 capsules per minute. That’s 120,000 capsules per hour! You get increased production using your existing machine with no additional floor space or personnel.

ʨ Immediate productivy gains of up to 33% ʨ Quick and easy installation and removal

(you can easily change back to your current GKF 12 bore size parts)

ʨ Short payback period due to increased productivity

ʨ Original Bosch parts with full factory warranty

ʨ No machine modifications required ʨ Upgrade kit available for any GKF / DMW

12 bore machine

Your benefits

Non-Syntegon to Syntegon machine conversion kit.



Improve machine performance

Conversion Kit part numbers

1500 12 bore aluminum to 12 bore aluminum ʨ PK_8110401214

1500 12 bore bronze to 12 bore aluminum ʨ PK_8110401215

2000 12 or 16 bore aluminum to 16 bore aluminum ʨ PK_8110401216

Syntegon Technology Services has a kit available that will convert your non-Syntegon 1500 or 2000 capsule filling machine into a Syntegon 1500 or 2000.

This kit replaces all of the expensive and hard to obtain non-Syntegon parts that are not interchangeable with Syntegon parts. This will allow you to order all of your replacement parts and tooling from Syntegon, which will save you money and will result in better machine performance.

Figure 1 — Upgrade Kit

Powder Diverter Upgrade Kit.

Subject to alteration | February 2021 | PA-PCS/PRM-US


Lower weight variations through consistent level of product

DescriptionDuring normal production, powder in the dosing area becomes unevenly distributed, possibly resulting in inconsistent weight distribution. Powder Diverters redistribute product and even out the product level, thus reducing weight variations.

GKF 330/400/700/705, plastic Kit part number 8111347359 includes:

DMW 1500/2000 and GKF 1200/1500, plastic Kit part number 8111347360 includes:

8111347377All DMW & GKF machines

8111347379DMW 1500/2000 & GKF 1200/1500 machines11.4” long

8111347378All DMW & GKF machines except 130/330/400/700/701/702/705

8111347380All DMW & GKF machines

8111341288 - Plastic8111348252 - 316 SS

DMW 1500/2000 & GKF 1200/1500 machines

*Requires an 8mm hole be drilled and tapped in center of dosing disc 8111348251 - Plastic

8111348250 - 316 SSGKF 330/400/700/705 machines

8111347414 - Plastic 8111348248 - 316 SSGKF 330/400/700 machines

8111335890 - Plastic8111348254 - 316 SSDMW 1500/2000 & GKF 1200/1500 machines

ʨ 8111348251, quantity 1 ʨ 8111347378, quantity 2 ʨ 8111347414, quantity 1 ʨ 8111347377, quantity 2 ʨ 8111347380, quantity 2

ʨ 8111335890, quantity 1 ʨ 8111341288, quantity 1 ʨ 8111347380, quantity 2 ʨ 8111347377, quantity 2 ʨ 8111347378, quantity 2 ʨ 8111347379, quantity 1

Powder Station Upgrade Kit.



GKF 2000 Powder Station Upgrade Kit part number ʨ 8109600906

Figure 1 — Powder Station Upgrade Kit

Syntegon offers a kit to upgrade older GKF 2000’s to the improved powder station design found on the newer models.

The main benefit of this upgrade is that the wiper block is secured with a sturdy arm attached to a center mounting hub which prevents the wiper block from lifting during the upstroke of the transfer pins. The wiper block lifting issue is a common problem when running sticky powders with the old spring mounted design which will result in inconsistent fill weights, excessive powder loss, and bent or cracked bowl covers.

Another benefit of this upgrade kit is for customers who operate both older and newer GKF 2000’s who want powder station parts interchangeability between the old and new machines and standardized operator training and SOP’s.

The kit includes all of the parts shown in the picture and can easily be installed by simply removing the old parts and bolting on the new parts. Some older dosing discs may require that two threaded holes be added for the center mounting hub.

Simplified Cleaning Station Upgrade Kit.



ʨ Minimize capsule separation problems due to less product residue left on segments

ʨ Increase yields by increasing capsule separation efficiency

ʨ Decrease frequency of manually cleaning the segments

ʨ Easy on-site installation ʨ Can also replace older cam driven segment

cleaning station

ʨ Stationary device, no table top through hole required for vertical motion

Your benefits

Increase line efficiency through better capsule separation

Older GKF machines were ordered with or without a cleaning station. If your product characteristics or machine usage has changed, your can add a cleaning station to a machine that does not have one. This easily installed upgrade will result in lasting improvements of efficiency with only a nominal investment and virtually no down-time to install.

Figure 1 — Cleaning Station for 12-bore Figure 2 — The cleaning station installed on a 16-bore machine

Kit part numbers

GKF 1200 & 1500 12 bore machines ʨ 8111352709

GKF 1200 & 1500 16 bore machines ʨ 8111353265

Sticky Product Upgrade Kit.



Kit part numbers

DMW 2000 package ʨ 811347354

GKF 1200 & 1500 with bronze guide ring ʨ 8111347352

GKF & DMW 1500 with aluminum guide ring ʨ 8111347353

The best solution for products with sticky characteristics

If you do, then you know the many problems sticky products can cause. At Syntegon Technology Services, we have researched solutions for these problems and have developed a series of plastic parts to help you in your manufacturing efforts. Let us know what your needs are. We are confident we have the solutions.

Do you run products that have sticky characteristics?

Tamping Shaft Bearing Seal Upgrade Kit.



Kit part numbers

ʨ Bronze guide ring: 8111387492 ʨ Aluminum guide ring: 8111387491

Eliminate powder contaminationSyntegon Technology Services has developed seal kits to prolong the life of expensive tamping shaft bearings by eliminating powder contamination. These seal kits are easily self-installed in a couple of hours or less.

Fig. 1: Bronze guide ring, part number 8111 387 492 Fig. 2: Aluminum guide ring, part number 8111 387 491

Applicable equipment

ʨ GKF 1200/1500 machines with fixed bronze guide rings ʨ GKF 1500 and DMW 1500/2000 with

aluminum guide rings

Breakaway Style Closing Pins.



ʪ The PET Plastic closing pins will break off in the event of a crash and reduce the possibility of damage to your lower segments

ʪ The Aluminum and PET Plastic closing pins will break off cleanly at the score line in the event of a crash and reduce the possibility of fragmentation

ʪ The slight flexibility of the PET Plastic closing pin helps to reduce capsule defects in the event of a minor misalignment

Your benefits

Fig. 1 Stainless Steel closing pin Fig. 2 PET Plastic closing pin Fig. 3 Aluminum closing pin

Capsule Size Diameter Part Number Qty.00 - 000 0.236 8111373807 1

1 - 0 0.187 8111373806 14 - 2 0.157 8111373805 1

Syntegon now offers three styles of breakaway closing pins for your GKF encapsulation machine. The closing pins are available in the following material and sizes:


1 - 0 0.187 8111334723 14 - 2 0.157 8111334721 1


1 - 0 0.187 8111393576 14 - 2 0.157 8111393574 1

Aluminum

Stainless Steel PET Plastic

Cleaning/Ejection Station Brush Upgrade.



Do you have to stop your GKF or DMW capsule filler frequently to hand brush clean your segment bores because of sticky product residue?

Syntegon now offers an upgraded cleaning/ejection station with brushes. This product allows you to automatically keep your segment bores clean with mechanical scrubbing and compressed air.

This upgrade will greatly increase your yields by reducing or eliminating capsule separation problems. It will also reduce or eliminate machine downtime for manual cleaning.

Machine Model Types

Complete Cleaning StationBlock with Pins for Brushes

Cleaning Station Replacement Pins for Brushes

Ejection Station Pins for Brushes

DMW 2000 8111397139 8111397137 8110401543

GKF 400 8110418459 8111398868

GKF 700 8111398867 8111398868 90022000519

GKF 701 8111398867 8111398868 90022000519

GKF 702 8111398867 8111398868 90022000519

GKF 705 8110407127 8111398868 90022000519

GKF 1200 8111397138 8111397137 8110401543

GKF 1400 Coming Soon

GKF 1500 8111397138 8111397137 8110401543

GKF 1505 old 8110402140 8110402141 90022000518

GKF 1505 new* 8110417906 8110402141 90022000518

GKF 2000/2500 8110403225 8110402141

GKF 2500 ASB 100% 8110421917 8110402141

GKF 3005 8110402467 8110402141 90022000518

Cleaning/Ejection Station Replacement Brushes Part Numbers

8104237939 Size 0008104237940 Size 008104237941 Size 0 - 18104237942 Size 1 - 28104237943 Size 2 - 38104237944 Size 4 - 5

Note: Service life of cleaning/ejection brushes is approximately 20 hours.

GKF 705 cleaning station for brushes (brushes not shown and sold separately)

GKF 1500 cleaning station for brushes (brushes sold separately)

GKF 2000 cleaning station for brushes (brushes sold separately)

* Must verify part #8109608733 is in machine bill of material

Counter Closing Block.

Subject to alteration | November 2020 | PA-PCS/PRM-US


ʪ Prevents dented capsules

ʪ Easy replacement

Your benefits

Machine Types Counter Closing Block Stainless Steel with rub-

ber pad

Counter Closing Block Aluminum with rubber

pad

Counter Closing Block Plastic with

rubber pad

Replacement Rubber Pad

GKF 1505/3005 90022000509 90022000510 90022000511 900228110410146

GKF 2000/2500 90022000512 90022000513 90022000514 90022JHL709

GKF 700, 701, 702, 705 90022000515 N/A N/A 900228110410142

GKF 1500 N/A N/A 90022000516 900228110410148

DMW 2000 N/A N/A 90022000517 900228110410148

Syntegon now offers counter closing blocks with rubber pads for GKF and DMW capsule fillers. The rubber pad helps to prevent dented capsules when additional closing force is required. The rubber pad can be easily replaced as needed.

Replaceable rubber pad

Recommended glue: Barge’s all-purpose cement

Dosing Disk for GKF Capsule Fillers.



ʪ Simplify cleaning process ʪ Minimize changeover times ʪ Reduce damage to machine working parts ʪ Minimize machine crashes and downtime ʪ Decrease product loss ʪ Increase run times

Your benefits

Do you have trouble running sticky and/or heavy products on your Syntegon capsule filling machine? Syntegon has the solution for you.

The Nylatron® dosing disk is ideal for machines running in high humidity environments and for machines running heavy and/or sticky products. It can also be used for testing new products whose characteristics are unknown.

Fig. 1: Nylatron® dosing disk

MachineModel

Capsule Size

00 0 1 2 3 4DMW 2000 8110413402 8110413403 8110413404 8110413405 8110413406 8110413407

Height mm 15.0 - 24.0/25.3 15.0 - 21.8/24.0 15.0 - 19.9/21.5 15.0 - 17.4 15.0 - 16.6 15.0 - 17.2 (4el)

GFK 400 8110412444 8110412445 8110412446 8110412447 8110412448 8110412449

Height mm 12.0 - 24.0/25.3 12.0 - 21.8/24.0 12.0 - 19.9/21.5 12.0 - 17.4 12.0 - 16.6 12.0 - 14.5/17.2

GKF 700/705 8110412420 8110412421 8110412422 8110412423 8110412424 8110421425

Height mm 12.0 - 24.0/25.3 12.0 - 21.8/24.0 12.0 - 19.9/21.5 12.0 - 17.4 12.0 - 16.6 12.0 - 14.5/17.2

GKF 1500 8110412348 8110412349 8110412350 8110412351 8110412352 8110412353

Height mm 15.0 - 24.0/25.3 15.0 - 21.8/24.0 15.0 - 19.9/21.5 15.0 - 17.4 15.0 - 16.6 15.0 - 17.2 (4el)

GKF 1505 8110412020 8110412021 8110412022 8110412023 8110412024 8110412025

Height mm 17.0 - 24.0/25.3 17.0 - 21.8/24.0 17.0 - 19.9/21.5 17.0 - 17.4 N/A 17.0 - 17.2 (4el)

GKF 2000 new style 8110412372 8110412373 8110412374 8110412375 8110412376 8110412377

Height mm 17.0 - 24.0/25.3 17.0 - 21.8/24.0 17.0 - 19.9/21.5 17.0 - 17.4 N/A 17.0 - 17.2 (4el)

GKF 3005 8110412396 8110412397 8110412398 8110412399 8110412400 8110412401

Height mm 17.0 - 24.0/25.3 17.0 - 21.8/24.0 17.0 - 19.9/21.5 17.0 - 17.4 N/A 17.0 - 17.2 (4el)

Plastic Sorting Blocks and Sorting Fingers.



Undamaged lettering through plastic sorting blocks and sorting fingers

GKF and DMW 1500 Plastic Sorting Finger part numbers

GKF and DMW 1500 Plastic Sorting Block part numbers

8111332743 - Size 000 8111341963 - Size 000

8111332744 - Size 00 8111332752 - Size 00

8111332745 - Size 0 8111332754 - Size 0

8111332746 - Size 1 8111332755 - Size 1

8111332747 - Size 2 8111332756 - Size 2

8111332748 - Size 3 8111332757 - Size 3

8111332749 - Size 4 8111332758 - Size 4

8111332750 - Size 5 8111332759 - Size 5

Problems with defective capsules due to scraped or scuffed lettering?

At Syntegon Technology Services,we have engineered Plastic Sorting Blocks and Plastic Sorting Fingers, components which directly contact the capsule during the sorting process. Many of our customers have found this to be a viable solution to their problems.

We also offer plastic components to fit GKF 400 and GKF 700 model machines.

Figure 1 — Plastic Sorting Blocks and Sorting Fingers

Plastic Wiper Block Shoe.



Eliminate damage to the surface of the dosing disk

Machine Types Nylatron® (used with sticky products)

PET (used with standard products)

GKF Capsylon 705 8110408067 N/A

GKF Capsylon 1505 8110404710 8110404711


Syntegon Technology Services now offers a Nylatron® and a PET plastic wiper block shoe for your GKF capsule filling machine. This will eliminate the damage to the surface of the dosing disk in the event of incidental contact between the shoe and the disk.

*Nylatron® is a registered trade name of Quadrant EPP.

Figure 1 — GKF Capsylon 1505 Nylatron® wiper block shoe

Figure 2 — GKF Capsylon 3005 Nylatron® wiper block shoe

Powder Augers.



ʪ Increased versatility

ʪ Improved product handling

ʪ Better product feeding

ʪ Guaranteed to fit your machine

Your benefits

Syntegon offers a wide range of powder augers in both plastic and 316L stainless steel to suit your needs. Having a variety of powder augers on hand improves the versatility of your capsule filler.

Auger Type GKF 400, 700, 701, 1200, 1500DMW 1500, 2000

GKF 1400, 1505, 2000, 2500, 3005

GKF 705

3 Twist Plastic N/A 8109619431 N/A

4 Twist Plastic, old style short

N/A N/A 8104619567

4 Twist Stainless, old style short

N/A N/A 8111390333

5 Twist Plastic N/A 8104236126 N/A

5 Twist Stainless N/A 8111350684 N/A

8 Twist Plastic 8111348352 8111350978 N/A

8 Twist Stainless 8111350676 8111350979 N/A

13 Twist Plastic 8104226985 N/A N/A

13 Twist Stainless 8111350677 N/A N/A

1/4 Twist at end only Plastic

8111334698 N/A 8104619768

1/4 Twist end only Stainless

Available/Call N/A N/A

Flat Blade Plastic 8111337316 N/A N/A

Flat Blade Stainless

Available/Call N/A N/A

Flat Blade with 1/4 Twist Plastic

N/A 8111353554 N/A

New style full-length

N/A N/A 8109608218

Slinger/catch disk Mounts to bottom of auger for free flowing powders

Stainless 8111364310 8104233659 8104233659

Red polyurethane 8104220287 8104238783 8104220287

Powder Bowl Cone.



GKF 2000 part numbers: ʪ 8111346303 - Plastic ʪ 8111348256 - 316 Stainless Steel

Outstanding outcome through improved powder dispersion

Syntegon Technology Services now offers a new powder bowl cone to improve powder dispersion over the dosing disk. It can be mounted to either a fixed or adjustable dosing disk. The cone installs in minutes with the supplied hardware and requires no modifications.

Note: The powder bowl cone can only be used with machines that have the transfer station powder diverter block mounted to the dosing bowl cover. The powder bowl cone cannot be used with center mounted transfer station powder diverter blocks.

Tamping Pin Guide Rings.



Are you running sticky or abrasive products?

At Syntegon Technology Services we have researched solutions for these problems and have developed Plastic Bushed Guide Rings. The plastic bushings provide a non-stick surface, which enables the tamping pins to actuate in a sticky situation, with virtually no restrictions. Let us know what your needs are. We are confident we have the solutions.

Syntegon Technology Services can also rebush your current bushed guide ring or we can bush your non-bushed guide ring.

Machine Models Stock without plastic inserts

With PET plastic inserts

GKF 400 8104225154 8111398300

GKF 700 & 701 8104226952 8111349032

GKF 705 8104619526 90022JHL623

GKF 1200/1500 with fixed bronze

8108674737 8111348289

GKF 1400 8104503651 8111398299

DMW & GKF 1500 (12 bore) 30 MM

8108220292 8111322820

GKF 1500 40 MM 8108222239 8111341573

GKF 1505 8104619808 8109608114

DMW 2000 (16 bore) 8111346369 8111347137

GKF 2000 8104552264 8111347134

GKF 2500 8104235280 90022JHL622

GKF 3005 8104236550 90022JHL624

Tamping Ring for Sticky Products.



Machine Model Part #GKF 330 and GKF 400 (older) 8110412540

GKF 400 (newer) and GKF 700 8111386761

GKF 701 8113390298

GKF Capsylon 705 8111390338

DMW 2000 and GKF 1500 without exhaust port

8111386180

DMW 2000 and GKF 1500 with exhaust port

8110409264

GKF 2000 8111386883

GKF 2500 w/o slide gates 8111388688

GKF Capsylon 1505 8111388688

GKF Capsylon 3005 8111388688

Do you have trouble running sticky products on your GKF or DMW Capsule Filler? Syntegon has the solution for you.

Syntegon has researched solutions for sticky products and we have developed a tamping ring made out of a new plastic material called Nylatron®.

Our testing has shown that Nylatron® has better wear characteristics and creates less friction than PET.

Nylatron® is a registered trade name of Quadrant EPP.

Alignment Pins.

Subject to alteration | October 2020 | PA-PCS/PRM-US


ʪ Segment Alignment Pins Precisely aligns upper to lower segments

Part Number Size8108219720 000

8108219730 00

8108219740 0

8108219750 1

8108219760 2

8108219770 3

8108219780 4

8108219790 5

8111339544 00 V-Cap

8111341546 0 V-Cap

Perfectly align your encapsulation machine by using OEM Alignment Pins from Syntegon, and maximize your efficiency and production!


8104233812 00

8104233813 0

8104233814 1

8104233815 2

8104233816 3

8104233817 4

8104233818 5


8111338332 00

8111338333 0

8111338334 1

8111338335 2

8111338336 3

8111338337 4

8111338338 5


8111344940 0

8111344941 1

8111344942 2

8111344943 3

8111344944 4

ʪ Dosing Disk Alignment Pins Dosing disk is located in perfect alignment with the tamping pin guide ring

ʪ Sorting Block Rectifier Pins Concentricity within the sorting block slots to the bores of the segments can be precisely located

ʪ Transfer Station Alignment Pins Create ideal alignment between the segment and closing turrets, lower segments and dosing disk

Grease Applicator Tools.



Precise and efficient grease application

Size (mm) Part Number GKF Machine Models10 8110404275 701, 702, 705, 1400, 2500

12 8111336520 400, 700, 701, 702, 705, 1200, 1500, 1505, 2000, 2000 16 bore, 2500, 3000, 3005

12 long 8111336519 400, 700, 1200, 1500, 2000 16 bore

16 8110404273 1400

16 long 8111336295 1200, 1500, 2000 16 bore

20 8111336518 400, 700, 701, 702, 705, 1200, 1500, 1505, 2000, 2000 16 bore, 2500, 3000, 3005

25 8111336517 400, 700, 701, 702, 705, 1400, 1505, 2000, 2500, 3000, 3005

30 8111336516 1200, 1500, 2000 16 bore

50 8110404271 1400

60 8111336515 1200, 1500, 1505, 2000, 2000 16 bore, 2500, 3000, 3005

Greatly improve the speed and thoroughness of grease application to the linear ball bearings on your Syntegon encapsulator. Save time when replacing damaged bearings or during scheduled preventive maintenance.

Complete applicator kit for GKF 1200 and 1500 and DMW 1200 and 1500 ʨ Part number 8111347356 (includes 60mm, 30mm, 20mm, 16mm long, 12mm, 12mm long)

Complete applicator kit for GKF 400 and 700 ʨ Part number 8111347355 (includes 25mm, 20mm, 12mm, 12mm long)

Lower Segment Carrier Alignment Tool.



Eliminate downtime caused by improperly aligned segments

Machine Model Part #GKF 701, 702, 705 8109600879GKF 1400 8104500249GKF 2000, 2500 8109600958GKF 1505, 3005 8109607895

Capsule splits and poor separation can be caused by improper parallel alignment between the upper and the lower segments. This simple, easy to use tool helps to align the parallel position of the lower segments on your equipment.

Alignment Tool for GKF 2000

ʪ Easy to install and use

ʪ Eliminate lower segment alignment errors

ʪ Reduces lower segment holder installation time

ʪ Upper segments align faster and easier when lower segments are aligned properly

Your benefits

Rectifier Alignment Pins.



High precision alignment with Rectifier Alignment Pins

Eliminate the “eyeball” method from the rectifier cage alignment procedure on your GKF encapsulators. Guaranteed accuracy of alignment is critical for proper capsule separation. Utilization of the Rectifier Alignment Pins is an inexpensive way to ensure proper machine functionality. By using the Rectifier Alignment Pins from Syntegon, concentricity within the sorting block slots to the bores of the segments is set to factory specifications, which maximizes your efficiency and production!

Fig. 2 Rectifier Alignment Pin

Fig. 1 A = Alignment Pins placed in a GKF encapsulator

A

Capsule Size Part Number000 8111338331

00 8111338332

0 8111338333

1 8111338334

2 8111338335

3 8111338336

4 8111338337

5 8111338338

All GKF and DMW modelsRectifier alignment pin part numbers

Segment Turret Gearbox Alignment Tool.



ʪ Easy to install and use

ʪ Reduces segment turret alignment time

Your benefits

Machine Model Part NumberGKF Capsylon 1505 8110421422GKF Capsylon 3005 8110421422

GKF 2000 8110421422GKF 2500 8110421422

Greatly reduce the time required to align the segment turret gearbox after a crash or gearbox replacement. The segment turret gearbox is aligned to the segment turret cam. This tool will bring you within approximately .005” making the final alignment quick and effortless.

Sticky Product Package.Do you have trouble running sticky products on your capsule filling machines? Syntegon has the solutions for you.

1. PET Plastic Closing Pins2. Plastic Wiper Shoe Block3. Tamping Pin Guide Rings with plastic inserts4. Cleaning/Ejection Station Brushes5. Nylatron® Dosing Disc6. Nylatron® Tamping Ring

4

3

5

6

21

Capsule Size Diameter Part Number Qty.

00 - 000 0.236 8111393575 1

1 - 0 0.187 8111393576 1

4 - 2 0.157 8111393574 1

Machine Model Nylatron® (used with sticky products)

PET (used with standard products)


GKF Capsylon 1505 8110404710 8110404711


Machine Model Part Number

GKF 400 8111398300

GKF 700 & 701 8111349032

GKF 705 90022JHL623

GKF 1200 / 1500 with fixed bronze 8111348289

GKF 1400 8111398299

DMW & GKF 1500 (12 bore) 30 MM 8111322820

GKF 1500 40 MM 8111341573

GKF 1505 8109608114

DMW 2000 (16 bore) 8111347137

GKF 2000 8111347134

GKF 2500 90022JHL622

GKF 3005 90022JHL624


1. PET Plastic Closing Pins ʪ Will break off cleanly at the score in the event of a crash and

reduce the possibility of fragmentation and damage to your lower segments

2. Plastic Wiper Block Shoe ʪ Eliminate damage to the surface of the dosing disk in the event of

incidental contact between the shoe and disk

3. Tamping Pin Guide Rings ʪ Provide a non-stick surface which enables the tamping pins to

actuate in a sticky situation, with virtually no restrictions



4. Cleaning/Ejection Station Brushes ʪ Automatically keep your segment bores clean with mechanical

scrubbing and compressed air

Machine Model Complete Cleaning Station Block with Pins for Brushes

DMW 2000 8111397139

GKF 400 Coming soon

GKF 700 8111398867

GKF 701 8111398867

GKF 702 8111398867

GKF 705 8110407127

GKF 1200 8111397138

GKF 1400 Coming soon

GKF 1500 8111397138

GKF 1505 8110402140

GKF 2000/2500 8110403225

GKF 3005 8110402467

Brush Part Numbers

Note: Service life of cleaning/ejection brushes is approximately 20 hours

Machine Model Part Number

GKF 330 8110412540

GKF 400 (older) 8110412540

GKF 400 (newer) 8111386761

GKF 700 8111386761

GKF 701 8111390298

GKF Capsylon 705 8111390338

GKF 1500 8111386180

DMW 2000 8111386180

GKF 2000 8111386883

GKF 2500 w/o slide plates 8111388688

GKF Capsylon 1505 8111388688

GKF Capsylon 3005 8111388688

Machine ModelCapsule Size

00 0 1 2 3 4

DMW 2000 8110413402 8110413403 8110413404 8110413405 8110413406 8110413407

GFK 400 8110412444 8110412445 8110412446 8110412447 8110412448 8110412449

GKF 700/705 8110412420 8110412421 8110412422 8110412423 8110412424 8110421425

GKF 1500 8110412348 8110412349 8110412350 8110412351 8110412352 8110412353

GKF 1505 8110412020 8110412021 8110412022 8110412023 8110412024 8110412025

GKF 2000 8110412372 8110412373 8110412374 8110412375 8110412376 8110412377

GKF 3005 8110412396 8110412397 8110412398 8110412399 8110412400 8110412401

Capsule Size Part Number

Size 000 8104237939

Size 00 8104237940

Size 0-1 8104237941

Size 1-2 8104237942

Size 2-3 8104237943

Size 4-5 8104237944


5. Tamping Ring ʪ Made with a plastic material called Nylatron®; our testing has

shown Nylatron® to have better wear characteristics and create less friction than PET

6. Dosing Disk ʪ Made with a plastic material called Nylatron®; simplifies the cleaning process, minimizes changeover times, and increases run times

Transfer Station to Segment Turret Aligment Pins.



High precision transfer station alignment pins

Capsule Size Part Number00 81113449390 81113449401 81113449412 81113449423 81113449434 8111344944

With Syntegon alignment pins, you can create perfect alignment between the segment and dosing turrets, lower segments, and dosing disk.

ʨ The segment turret alignment should be verified and/or corrected before checking transfer station alignment. ʨ Two alignment pins are placed on opposite ends of a lower segment and indexed to the powder transfer

station. Dosing disk bolts are left finger tight to allow rotational adjustment.

ʨ Using the supplied screws, pass through the dosing disk and thread into the alignment pins and pull them into the dosing disk. If the pins cannot be pulled into the dosing disk, move the dosing gearbox to correct the alignment.

ʨ Once the pins can be pulled into the dosing disk, tighten the dosing disk bolts. ʨ Use the dosing disk alignment pins to check alignment between dosing disk and tamping pin guide ring. If

alignment is not correct, loosen tamping shaft pillow blocks and adjust until alignment is correct.

Figure 1 — Segment Turret Alignment Pins

Transfer Station Alignment Pin part numbers

Upper Segment Carrier Alignment Tool.



Eliminate downtime caused by improperly aligned segments

Capsule splits and poor separation can be caused by improper parallel alignment between the upper and the lower segments. This simple, easy to use tool helps to align the parallel position of the upper segments.

Part number ʪ 8111351146

Applicable equimentGKF1200, GKF 1500, DMW 1500, and DMW 2000

Capsule Filler Tooling Wear Gauge Sets.



Capsule Size Part Number000 8111354782

00 8111354783

0 8111354784

1 8111354786

2 8111354787

3 8111354788

4 8111354789

5 8111354790

Measuring the wear on your Syntegon GKF and DMW tooling is a very important procedure. This procedure, when performed routinely, will help you to determine when your tooling is worn to the point where it needs replacement in order to maintain optimum performance.

Syntegon has capsule filler tooling wear gauge sets for every capsule size.

Kits include:1 each - Upper segment upper bore pin1 each - Upper segment lower bore pin1 each - Lower segment upper bore pin1 each - Dosing disk bore pin1 each - Tamping pin tip ring gauge1 each - Case and instruction sheet

9L Filtered Pre-Separator.Increases the filter capacity and filtering efficiency of your capsule separation vacuum system



Product InformationPart Number Description8111365221* Filter canister, 9L with 30MM, painted with HEPA8111365222* Filter canister, 9L with 30MM, stainless steel with HEPA8111365225 HEPA filter, 9L filter canister8111365224 Filter bag, 9L filter canister, polyester90022000508** Coupler, silicone, 1.5”ID x 4.0”L

ʨ Install anywhere in-line between your separation vacuum pump and encapsulation machine. ʨ Large filter surface area reduces frequency in which the filter needs to be cleaned. ʨ HEPA filter captures 99.97% of particles down to and including 0.3 microns in size. Originally supplied

separation filters only capture 99.9% of particles down to and including 5 microns.

ʨ Minimize the amount of product that reaches your vacuum pump, reducing vacuum pump maintenance and downtime.

* Painted or stainless steel filter canister comes with HEPA filter and filter bag** 2 couplers are required for each filter canister order

Capsule Polisher.



ʨ Connect to any capsule filler ʨ Dual stage brush system for clean capsules ʨ Simple disassembly for cleaning ʨ 100% wash down capable ʨ Processes capsules from size 5 to 000 ʨ Connection for dust collection ʨ Variable speed control

Your benefits

Our new capsule polisher has a very robust design. It can be connected to and will keep up with any capsule filler on the market. Because of the innovative and unique dual stage brush system, this polisher will completely clean capsules regardless of how much powder is discharged out of your capsule filler. It is very simple to disassemble for cleaning and you can hose down the entire polisher, as it is 100% wash down capable.

The optional capsule discharge chute blockage sensor assembly can be used on any Capsylon with a serial number of 726899 or higher. This optional assembly will stop the Capsylon in the event of capsules backing up into the discharge chute. This optional assembly is plug and play with no wiring or programming changes required.

Fig. 1 - Capsule Polisher unit attached to a GKF Capsylon 3005

Fig. 2 - Brush assembly

Fig. 3 - Optional capsule discharge chute blockage sensor assembly

Item Part #

Capsule Polisher 90022JHL400

Replacement stage 1 short brush (2 required)

90022JHL394

Replacement stage 2 long brush 90022JHL155

Optional capsule discharge chute blockage sensor assembly

8109608311

Capsule polisher with empty capsule eliminator

Dust Collection Systems.

Replacement Cartridge Filters3707/10 requires 4x 8111 361 3863306/3307/3308/T63 PLUS/ requires 3x 8111 361 386VHW420

Replacement Upstream HEPA Filters3307/3507 requires 1x 8111 347 0773308/3508W requires 1x 8111 360 8093707/10 requires 1x 8111 350 679T63 PLUS requires 1x 8110 402 142

Replacement Downstream HEPA Filters3156 requires 1x 8111 396 3383306 requires 1x 8111 377 386VHW420 requires 1x 8110 402 686

All dust collection systems include all necessary hoses and fittings to connect to the dust collection hardware supplied with your machine.

Models T63 Plus, 3707/10 and VHW420 available in painted or stainless steel.

Replacement Main Star Bag Filter3156 requires 1x 8111 370 744

Polyliners for collection container3707/10 1/ea. 8111 350 7553307/3308/3580W/ 25/pkg. 8111 350 754T63 PLUS3306 25 pkg. 8111 375 235VHW420 25 pkg. 8110 400 125VHW420 polyliner adapter kit, galvanized 1/ea. 8110 400 126VHW420 polyliner adapter kit, 304 SS 1/ea. 8110 400 127

Applicable Equipment *GKF 120, GKF 130, GKF 330, GKF 400, GKF 700, GKF 701, GKF 702, GKF 705, GKF 800, GKF 1200, GKF 1400, GKF 1400 ASB 100%, DMW 1500, GKF 1500, GKF 1505, DMW 2000, GKF 2000, GKF 2500, GKF 2500 ASB 100%, GKF 3000, GKF 3005

* Please call your customer service representative to determine the correct dust collection model for your GKF capsule filling machine.



System Specifications

Units T63 PLUS 3707/10 VHW420

Voltage @ 60Hz Volts 200-240/440-480 440-480 only 220/460/575

Type of Power # of phases 3 3 3

Power KW 6.3 9.0 2.52

Current Draw Amps 25.0/13.3 19.6 11.4 / 6 / 4.55

Waterlift, controlled Inches H20 82.6 92.3 76.0

Airflow, Max. CFM 345 518 222

Filter Area, cartridge Sq. Ft. 56.5 75.4 21.5

Filter Area, HEPA(upstream)

Sq. Ft. 37.7 129.2 22.6

Noise Level dB(A) 71 @ 1.5m 78 @ 1m 66 @ 1.5m

Tank Capacity Gallons 26 46 12.6

Machine Inlet Inches 3 4 2.8

Dimensions (LxWxH) Inches 50.8 x 23.6 x 64.6 63 x 31.5 x 71.3 38.1 x 21.2 x 54.8

Weight Pounds 367 672 220

Cord Length Feet 30 30 30

Filter Efficiency, HEPA(DOP-Tested)

% 99.95% @ 0.18microns

99.97% @ 0.3 microns

99.95% @0.18microns

Empty Capsule Conveyor.



Product SpecificationsElectrical supply** 460V, 3 Phase, 1.5AWaterlift 47.5 in. H₂OHopper capacity In excess of 1 boxPower 0.67 HPAirflow 46 CFMDimensions 24”L x 47”W x 40”H

The Nilfisk® Empty Capsule Conveyor model 9505 is designed to convey empty capsules sizes 000 - 5 at a rate in excess of the highest output Syntegon capsule filler. This unique conveyor uses a blower to gently push the capsules through rigid sanitary piping without damage. The conveyor has a receiver hopper mounted via tri-clamp to the Syntegon capsule filling machine capsule inlet. The receiver hopper has an integrated level sensor making this a truly “plug and play” system with no electrical connection to the Syntegon capsule filler.

All capsule contact surfaces are constructed of AISI 316L stainless steel. The exterior of the machine is constructed of 304 stainless steel. The Nilfisk® 9505 uses HEPA filtration and a programmable PLC to maintain optimal operation. When the conveyor supply container runs low, an indicator light and/or audible alarm will alert the operator to refill the conveyor container which holds in excess of one box of capsules.

This conveyor will fully automate the loading of empty capsules into your Syntegon capsule filler and will eliminate the possibility of accidents and injuries to your operators when climbing ladders to fill the Syntegon capsule filler empty capsule hopper.

Empty Capsule Conveyor Part number ʨ 900228110413469*

* An additional HEPA filter is included in the price

** A 220V version is available as a special order

Slug Tester.Determine the optimal dosing disk height for any capsule size



1

2

3

4

5

6

7

8

Legend1. Slug Tester2. Resistance Handle3. Compression Pin4. Compression Die

5. Hand Wheel6. Die Holding Plate7. Control Panel8. Powder Tray

The slug tester is used to accurately determine the optimum dosing disk height for any size capsule (000, 00, 0, 1, 2, 3, 4, 5) relative to the product dosage required. It is also very useful in determining slug quality and simulates the transfer of the slug from the dosing disk to the lower capsule. The slug tester can also be used during the Research and Development phase of new products. The created slugs can then be used for dissolution testing and excipient usage determination.

Kit part number8111376670 – With custom hard sided case

Applicable EquipmentAll powder tamping capsule filling machines

All GKF machines.



GKF 700 GKF 701 GKF 702

GKF 1200 / 1500DMW 1500 / 2000

GKF 1400 GKF 2000 / 2500

GKF 2500 ASB 100% GKF 3000 GKF Capsylon 1505

GKF 702.Product development, product launch, high yield production



The Syntegon GKF 702 provides the best conditions for modern, flexible and safe production. Whether in the laboratory, for the production of clinical samples, or in industrial production, the Syntegon GKF 702 is a real all-around machine, which is suited for production in the product development phase through market introduction.

The modular layout allows modification or upgrade of the machine processes at any time, making the Syntegon GKF 702 a “future-proof” and safe investment. Long idle times for product changeovers are therefore a thing of the past.

The processing range of the Syntegon GKF 702 includes (micro) tablets, powder, pellets and even liquids and combination filling. Powder is dosed using the tamping pin method. For optimized batch yields, the patented slide-gate technology from the Syntegon GKF 1400 and GKF 2500 machine series is available as an option. With this system, free flowing granulates can be dosed in a very gentle manner. Additionally, the slide-gate technology can provide production flexibility by providing the ability to fill powders and pellets using the same station, thereby also reducing capital costs.

GKF 1200/1500 and DMW 1500/2000.Standard hard gelatin filling and closing machine for powder and pellets



With first rate, no-risk technology and highest experience potential, Syntegon has once again succeeded in setting a new standard with this hard gelatin capsule filling and closing machine.

The Syntegon GKF 1200 / 1500 , DMW 1500 / 2000 fulfills and even exceeds market requirements. In a precision functional process the capsules (which are fed pre-locked and non-oriented) are aligned, opened, filled and reclosed. Capsules inserted cap first or non-separated capsules, as well as capsules with two caps are recognized and rejected.

High filling accuracy is attained by a 5-up tamping procedure with minimal dust occurrence and without loss of product.

GKF 1400.Reliability in production



The Syntegon GKF 1400 includes all of our experience and know-how on secure capsule filling and closing of capsules. Like all of the GKF-series machines, it works with intermittent motion and doses powder via the proven tamping pin principle. Of course the machine is also capable of filling other types of products or combinations of products into hard gelatin capsules or gelatin-free capsules. Via the modular assembly of the capsule filler, the machine can be changed over to fill liquids in a short amount of time.

The Syntegon GKF 1400 offers great filling versatility through its flexible and modular design, allowing it to fill a large variety of product types. The Syntegon-patented slide-gate system guarantees a gentle and efficient pellet or powder filling. The machine control by means of an industrial PC makes possible the storage and management of production data. The WINDOWS-based software meets the requirements of 21 CFR part 11 in terms of data security.

Convincing technology and a trend-setting ergonomic design are a guarantee for pharmaceutical security, economy and particularly easy handling.

GKF 2000/2500.Pharmaceutical security for the most demanding requirements



Every year we develop new ways to increase the performance and efficiency of our GKF capsule filling machines. Over the years, our machines have evolved with smoother easy to clean surfaces featuring rounded corners, coatings that product won‘t stick to, and sealed shafts. Each of these features reduces the amount of time your team will spend cleaning the machine, increasing your profit by making the machine available to production as much as possible.

The Syntegon GKF 2000 and GKF 2500 are easy to operate. Simple control panels, single tool change overs, and reduced down time due to product jams makes for a more productive workforce that will have to spend less time tending to the machine and allows you to concentrate on growing your business.

GKF 2500 ASB Series.Optimized productivity through automation



The Syntegon GKF 2500 series of machines with automatic troubleshooting system (ASB) ensures optimized productivity and pharmaceutical security for the filling of capsules. Versions GKF 2500 ASB, GKF 2500 ASB IPK or GKF 2500 ASB 100%.

The high degree of automation ensured by ASB provides for smooth production processing and ensures optimized productivity with minimum downtimes.

The Syntegon GKF 2500 ASB IPK with in-process control makes it possible for you to perform weight control by way of statistical evaluation with documentation of the random sample data, daily batch and batch data.

The Syntegon GKF 2500 ASB 100% is equipped with an integrated checkweigher. Each capsule is weighed individually and with high precision. Accepted are only those capsules of which the weight is within the preset tolerance limits. Any overweight or underweight capsules are rejected.

GKF 2600.The flexible capsule filling platform



You want to fill your products into capsules flexibly and reliably? Then the modular machine platform of the GKF 2600 series is your ideal solution. Due to its flexibility and inspection technologies the capsule filling machine can be tailored to your products and requirements within next to no time.

The GKF 2600 is a highly flexible machine platform. It features interfaces and drives that are compatible with all filling stations. This way you can optimally process different products with changing parameters – at an output of up to 2,600 capsules per minute.

With the GKF 2600 you receive a compact capsule filling machine in the high-performance range. Based on many years of experience we have designed a future-proof platform that consistently adapts to your production requirements. The cGMP compliant machine meets all demands for the highest pharmaceutical safety.

The GKF 2600 offers you numerous technical advantages. Its flexible machine platform combines highest ergonomics, easy operation and cleaning, as well as safe processing for best capsule filling results.

GKF 3000.Maximum efficiency: high output, fast changing and cleaning



On the basis of the very successful Syntegon GKF 2500 S capsule filler we have launched the fastest tamping pin machine on the market: the Syntegon GKF 3000 S with an output of maximum 175,000 capsules per hour.

Whether you are processing powders, herbs or pellets, this machine achieves unsurpassed precision dosing with maximum output and minimum powder loss. Knowing that not only output makes a machine efficient, we have turned our attention to a reliable technology with short downtimes for changing, cleaning and low maintenance.

GKF Capsylon.Ideal for capsule filling of Pharmaceutical and Nutraceutical products



Wide range of filling productsThe Syntegon GFK Capsylon is a unique machine suitable for a wide range of filling products. This ranges from typical nutraceutical products such as herbs or vitamins to pharmaceutical products such as powder, pellets, granules, or even special products with sticky, abrasive, fibrous or other properties. The filling ingredients can be in the form of powder, granulates and pellets. The Syntegon GKF Capsylon can accomodate different nutraceutical products as needed.

Flexible machine with different outputsThe Syntegon GKF Capsylon offers excellent cost performance and flexible machine design. The segment alignment is stationed next to the filling station to minimize product loss before capsule closing. Furthermore, the smart design and experienced engineering allow easy and fast cleaning and format change over.

GKF Capsylon 705

GKF Capsylon 3005

GKF Capsylon 1505

KKE 1700.Maximum pharmaceutical security



The Syntegon KKE 1700 capsule checkweigher sets the standard in the field of 100% capsule weighing. The precise gravimetric weighing technology and ergonomic design make it the ideal choice for your capsule checkweighing needs.

A major feature of the Syntegon KKE 1700 is its easy accessibility. The integrated cGMP and ASB technology (automatic troubleshooting system) guarantee extremely high productivity. The permanent positive guidance of the capsules also guarantees maximum pharmaceutical s

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