Quick Fault Finder — Capsule Filling · Ask Dhanu

Guide4

Quick Fault Finder

Find the symptom, check the first causes listed, then open the full answer from its code.

Capsule Feeding, Orientation & Separation

Code	Problem	First causes to check
A-01	Capsules Not Feeding	Capsule hopper empty or not refilled; Capsules bridging in the hopper; Feeding disc not rotating
A-02	Capsules Bridging in the Hopper	Capsules interlocking; High static electricity; Hopper overloaded
A-03	Feeding Disc Not Rotating	Feeder motor overload; Loose drive coupling; Broken chain or belt
A-04	Capsules Jamming in the Machine	Broken or deformed capsules; Dirty guide track or capsule channel; Capsule upside down
A-05	Capsule Magazine Blocked	Broken capsules; Capsules too large or deformed for the magazine; Dust or debris in the magazine tracks
A-06	Incorrect Capsule Orientation	Incorrect feeder adjustment; Worn orientation block or misaligned orientation (sowing) plate; Damaged feeding disc
A-07	Double Capsule Feeding	Incorrect feeder adjustment; Worn feeding disc pockets; Excessive vibration
A-08	Broken Capsules in the Feeder	Poor capsule quality; Excessive feeding pressure; Damaged guide rails
A-09	Capsules Not Entering the Tooling	Powder covering the ball bearing and spring in the capsule gate channel
A-10	Capsules Not Separating	Vacuum pressure too low; filter blocked; hose or pipe leaking; Upper and lower segments misaligned; Segment holes blocked
A-11	Capsule Body Stuck in the Separator	Poor vacuum; Damaged separator bush; Dirty separator station
A-12	Capsule Cap Stuck	Low vacuum; Damaged cap holder; Separation timing incorrect
A-13	Missing Capsule Body or Cap	Poor separation; Low vacuum or vacuum failure; Incorrect separator adjustment or timing
A-14	Caps Drawn into the Rejection Station	Vacuum pump pressure out of calibration
A-15	Separation Plate Worn	Normal wear; Poor lubrication; High production hours
A-16	Separation Timing Incorrect	Incorrect machine set-up; Cam adjustment incorrect; Mechanical wear

Powder Dosing, Fill Weight & Tamping

Code	Problem	First causes to check
B-01	Capsules Empty or Powder Not Filling	Powder hopper empty; Powder bridging in the hopper; Dosing disc blocked
B-02	Fill Weight Too Low	Low powder level; Poor powder flow; Dosing depth or powder bed too low
B-03	Fill Weight Too High	Dosing depth or powder bed too high; High powder density; Incorrect calibration or machine settings
B-04	Weight Variation	Poor powder flow or bridging; Powder segregation; Variable hopper level
B-05	Automatic Powder Feeder Not Feeding	Powder container empty or pick-up tube above the powder level; Powder bridging or rat-holing; Vacuum hose blocked, kinked or leaking

Powder Properties & Flow

Code	Problem	First causes to check
C-01	Powder Bridging in the Hopper	Poor powder flowability; High moisture content; Fine particle size
C-02	Poor Powder Flow	High moisture; Fine powder; Poor formulation flowability or insufficient glidant
C-03	Powder Segregation	Differences in particle size or density; Vibration during transport; Over-mixing or prolonged stoppage
C-04	Powder Compaction	High tamping pressure; Long production interruptions; Excessive powder load in the hopper
C-05	High Powder Moisture	High room humidity; Powder exposed too long or containers left open; Improper storage

Capsule Closing & Locking

Code	Problem	First causes to check
D-01	Capsules Not Closing Properly	Locking pressure too low; Closing plate gap out of specification or plate misaligned; Closing plate, pins or locking segments worn
D-02	Capsule Locking Failure	Incorrect or low locking pressure; Worn locking mechanism or closing cam; Closing station misaligned
D-03	Locking Pressure Too Low	Pressure set incorrectly; Low pneumatic pressure; Worn locking mechanism
D-04	Locking Pressure Too High	Pressure regulator set too high; Incorrect machine set-up; Operator adjustment error
D-05	Closing Plate Misaligned	Loose mounting bolts; Wear from extended operation; Incorrect maintenance adjustment

Capsule Defects & Discharge

Code	Problem	First causes to check
E-01	Broken Capsules	Poor capsule quality; Excessive locking pressure; Wrong size change parts
E-02	Cracked Capsules	Low humidity or moisture exposure; Excessive closing compression; Misaligned segments
E-03	Dented or Pin-Holed Capsules	Excessive pressure; Misaligned closing station; Damaged tooling or incorrectly sized / installed pins
E-04	Scratched Capsules	Sharp edges or burrs; Worn guide plates; Misaligned components
E-05	Capsules with Black Marks	Dirty tooling; Worn components; Oil contamination

Vacuum, Compressed Air & Dust Extraction

Code	Problem	First causes to check
F-01	Low Vacuum / Vacuum Low Alarm	Vacuum filter blocked; Vacuum leak; loose or cracked hose; Vacuum pump worn or failed
F-02	Vacuum Pump Failure	Motor failure; Bearing wear; Overheating
F-03	Vacuum Filter Blocked	Powder accumulation or capsule dust; Excessive product fines; Filter not cleaned
F-04	Vacuum Hose Leakage	Loose hose clamp; Cracked hose; Worn seals
F-05	Vacuum Breaker Keeps Tripping	Vacuum system overworked (blocked filter or full collection bag); Breaker set below the pump’s rated current

Drive, Motor & Mechanical

Code	Problem	First causes to check
G-01	Machine Will Not Start	No power supply; Emergency stop activated; Safety door open
G-02	Machine Stops Suddenly During Operation	Powder run out or powder outlet blocked; Loose or damaged mechanical part; Motor overload
G-03	Motor Runs but Machine Does Not Operate	Bolt on the motor’s main gear loose, so drive belt tension is lost; Overload clutch slipping
G-04	Main Motor Failure	Winding failure; Overheating; Bearing failure
G-05	Main Motor Overload	Machine overloaded or product jam; Bearing seizure; Mechanical obstruction or high friction

Electrical, PLC, Sensors & Safety Alarms

Code	Problem	First causes to check
H-01	Power Failure	Power outage; Main breaker tripped; Fuse blown
H-02	Circuit Breaker Tripped	Short circuit; Overload; Ground fault
H-03	Fuse Blown	Short circuit; Motor overload; Electrical fault
H-04	Emergency Stop Activated	Emergency stop pressed; Safety circuit activated; Door opened
H-05	Safety Door Open Alarm	Door or guard not closed; Faulty interlock switch; Broken wiring
H-06

GMP, Cleaning & Changeover

Code	Problem	First causes to check
I-01	Machine Not Properly Cleaned / Product Residue Found	Incomplete cleaning or wrong cleaning sequence; Hard-to-reach areas missed; Incorrect cleaning tools
I-02	Cleaning Verification Failure	Poor cleaning; Residual product; Incorrect cleaning chemicals
I-03	Cross-Contamination Risk	Poor cleaning; Incorrect line clearance; Shared equipment
I-04	Line Clearance Failure	Previous product not removed; Documents not updated; Wrong labels left on equipment
I-05	Wrong Product Loaded	Operator error; Labelling error; Poor line clearance

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