SEM-120-III (SERVO) Softgel Encapsulation Machine
Eight plungers, Φ150 × 120 die roll, full servo drive
You’ve outgrown a lab machine and a full 250 line is more than you need. This machine has the same servo architecture as our flagship — independent spindle drives, automatic die alignment, automatic filling volume adjustment — on a Φ150 × 120 die roll instead of a 250. Up to 115,200 capsules an hour at 3# oval.
- Output: up to 115,200 capsules an hour at 3# oval
- Filling accuracy: ±0.5% on oils, ±1.5% on suspensions
- Servo architecture: independent spindle drives and automatic die alignment, the same as our 250 flagship
- Power: 10 kW, 380 V / 60 Hz / 3-phase
Is this the right machine for you?
✓ Yes, if…
- You need more than 150,000 capsules an hour
- You run several capsule shapes and want settings recalled rather than re-tuned
- Your fill is a clean oil where ±0.5% is worth paying for
- You already have drying capacity for this output, or you're buying it with the machine
✕ Buy something else if…
- You need more than 115,000 an hour → the 250 series doubles the die roll length
- You run one shape and one recipe → the SEM-250-II is mechanical, higher output, and costs less than servo
- You're still developing the formula → the SEM-100II is the trial machine
Technical specification
Feature | SEM-120-III (SERVO) |
Die Roll Speed | 0 – 6 RPM (Servo Stepless Control) |
Die Roll Size | Φ120 × 150 mm |
Plunger Quantity | 10 – 12 Plungers (High Density) |
Filling Accuracy | ±1.0% |
Total Power | 12.0 kW |
Dimensions | 2150 × 1100 × 1950 mm |
Machine Weight | Approx. 1,400 kg |
Power Supply
| 380 V / 60 Hz / 3 Ph (Customizable) Approx. 1,200 kg → 1,200 kg |
Model comparison
Capsule size | SEM-100II | SEM-120-III | SEM-250-II | SEM-250-IIIA |
3# oval | 30,240 | 115,200 | 172,800 | 259,200 |
6# oval | 24,000 | 68,400 | 127,680 | 191,520 |
8# oval | 22,800 | 63,000 | 120,960 | 181,400 |
10# oval | 17,280 | 51,000 | 106,080 | 159,120 |
14# oval | 15,360 | 48,000 | 92,160 | 138,240 |
20# oval | 10,800 | 34,800 | 69,600 | 104,400 |
8# oblong | 18,240 | 49,200 | 109,200 | 163,800 |
10# oblong | 15,120 | 45,600 | 82,080 | 123,120 |
16# oblong | 13,680 | 32,400 | 69,120 | 103,680 |
20# oblong | 8,160 | 30,600 | 57,120 | 85,680 |
5# round | 24,480 | 79,200 | 158,400 | 237,600 |
10# round | 20,160 | 63,000 | 122,400 | 183,600 |
40# round | 5,760 | 27,600 | 66,240 | 99,360 |
Output depends on capsule size more than on anything else. A 3# oval and a 40# round come off the same machine at roughly a four-to-one ratio. Tell us your size and shape and we’ll give you the number for your product, not the headline one.
Advanced Full Servo Drive Technology
The SEM-120-III is equipped with an integrated servo system that eliminates complex mechanical gearboxes. Every movement—from die roll rotation to injection pump timing—is digitally synchronized, resulting in significantly lower noise, low vibration and reduced maintenance.
Precision Filling with Automatic Alignment
Powered by a high-precision servo injection system, the machine achieves a loading tolerance of±0.5% on oils and ±1.5% on suspensions. The digital interface allows for “micro-adjustment” of the injection timing during operation, ensuring zero waste and perfect fill-weight consistency.
Optimized High-Speed Die Roll (Φ120x150mm)
Featuring a larger die roll size compared to entry-level models, the SEM-120-III provides a higher density of mold pockets. This allows for a substantial increase in output (up to 30,600-115,200 pills/hour depending on size) while maintaining consistent seam pressure.
Intelligent Cooling Drum System
Equipped with a high-capacity internal cooling system, the machine maintains a constant temperature for the gelatin ribbon. The servo-controlled thickness adjustment ensures the ribbon is always uniform, even at higher speeds, preventing “thin spots” that lead to leaks.
Digital Recipe Management & Remote Support
The PLC-based HMI system can store hundreds of product recipes. Operators can switch between different capsule shapes or filling materials with a single touch, while the system’s internet connectivity allows for remote diagnostics and technical support.
Applications & Industries
What changing over involves
Swapping the mold is physical work. Recalling the settings is not
What changed | What you adjust | Roughly |
Same shape, new batch | Nothing on the machine | — |
Different fill, same shape | Injection timing and wedge temperature | 15-30 Mins |
Different capsule shape | Die rolls and injection pump swap, then recalibrate | 15-30 Mins |
Gelatin → vegan shell | Not a changeover. That’s a build configuration | — |
On the servo models, once a product is dialled in, speed, temperature, injection timing and ribbon thickness are stored as a digital profile. The mold still has to be swapped by hand — what you save is the recalibration afterwards.
Custom die rolls for a new shape take 2 to 3 weeks to machine and test.
What to check before you buy
Filling accuracy, and on which fill
Oil and suspension don't hold the same tolerance — ours are ±0.5% and ±1.5%. Ask any supplier which number applies to your product, and ask how it's verified at the factory acceptance test. A single headline figure usually means nobody has asked.
The manual
A clear English manual gets your operator running in a week instead of a month. Ask to see a sample page before you order.
Installation and training
One engineer to your plant, three to four weeks. Travel and on-site costs are quoted separately. Installation isn't free anywhere — it's either a line item or it's inside the machine price. We quote it as a line item so you can see it.
Why Choose AIPAK？
We Size the Whole Line, Not Just the Encapsulator
An encapsulator running at full speed produces more capsules than most buyers expect to dry. A Φ1000 tumbler line needs 16 to 18 sections to support 24-hour production, not the 10 that cover a single shift. We calculate your drying, gelatin melting and inspection capacity alongside the machine — before you order, not after.
Formulation Decides Configuration
Vegan shells need a different wedge, a different spreader box and a heated cooling drum. High-viscosity fills need a colloid mill upstream. Suspension products hold a different filling tolerance than oils. Tell us what you are encapsulating and we will specify around it, rather than sending a standard machine and hoping it fits.
Factory-Direct Engineering
You work with the engineers who build the machine. Mould shapes, feeder configurations and line layouts are a conversation, not a change order passed down a chain. Two years of spare parts and on-site installation and training are included.
Lead Time and Support
1-3months from order, confirmed in writing. Spare parts held at the factory. One engineer on site for installation and operator training.
Frequently Asked Questions (SEM-120-III SERVO)
Traditional mechanical machines rely on complex gears, chains, and cam systems, which are prone to wear, noise, and synchronization lag over time. The SEM-120-III (SERVO) utilizes independent digital motors for each core movement. This eliminates mechanical backlash, ensures near-silent operation, and allows for precise synchronization that remains perfect even after years of high-speed use.
In pharmaceutical and high-end nutraceutical production, even a 0.5% difference in filling accuracy can lead to significant ingredient waste over millions of capsules. Our servo-driven injection pump ensures the highest precision in the industry. By minimizing “overfilling” to meet label claims, the SEM-120-III can save you thousands of dollars in raw material costs annually, particularly when handling expensive oils or concentrated APIs.
Yes, the SEM-120-III is highly versatile. Vegan or starch-based ribbons require different temperature profiles and tension control compared to traditional bovine gelatin. Because our machine is full-servo, you can precisely adjust the ribbon tension and cooling drum temperatures via the HMI to accommodate the unique rheology of vegetable-based materials without hardware modifications.
The SEM-120-III features a “Zero-Waste” startup logic. The servo synchronization allows the injection timing to align perfectly with the die rolls from the very first rotation. Additionally, the micro-lubrication system ensures the gelatin ribbon is clean, meaning less cleaning time for the machine and higher yields of “ready-to-dry” capsules.
Switching between different capsule sizes (e.g., from 10 Oval to 20 Oblong) typically requires hours of mechanical calibration on older machines. With our Smart HMI, once a product is optimized, all parameters—speed, temperature, injection timing, and ribbon thickness—are saved as a digital profile. A changeover now only requires a physical mold swap; the technical settings are restored with one touch, reducing downtime by up to 50%.
Absolutely. The control system is built on a modern PLC architecture that supports Ethernet connectivity. We can provide remote diagnostic support to your facility anywhere in the world. Furthermore, the system can be integrated into your factory’s ERP or SCADA systems for real-time production monitoring, batch tracking, and OEE (Overall Equipment Effectiveness) analysis.
Maintenance is significantly reduced compared to mechanical models. There are no chains to tighten or complex gearboxes to lubricate. Primary maintenance involves standard cleaning of the GMP contact parts and routine inspection of the pneumatic seals. We provide a comprehensive preventive maintenance schedule and a “Fast-Response” spare parts kit with every machine to ensure zero unplanned downtime.
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