In short:Pharmaceutical machines need fast, repeatable servo motion that can be cleaned, contained and validated. Size each axis from the machine's output rate and cycle, then choose materials, sealing and controls that fit the cleanroom grade, the cleaning regime and the data-integrity rules the finished machine must meet.
Typical requirements
| High-speed tablet press output (published example) | Up to 1,380,000 tablets/h single layer, 115 stations at 100 rpm (KORSCH XT 600) |
|---|---|
| Tablet press compression force | 60 kN or 100 kN pre- and main compression (published press data) |
| Capsule filler output (published example) | 156,600 capsules/h at 145 cycles/min with 18 bores (Syntegon GKF 2600) |
| Washdown sealing | IP69K: 80 °C water at 80–100 bar from 100–150 mm |
| Hygienic actuator material | 316 stainless, welded seams, food-grade grease |
| Grade A / ISO 5 air | 3,520 particles/m³ at ≥0.5 µm (EU GMP Annex 1) |
| High-containment press (published example) | OEB 5, below 0.1 µg/m³, with wash-in-place |
Machinery we specify motion for
- Rotary tablet presses
- Capsule filling machines
- Powder and auger filling
- Liquid and volumetric filling
- Tablet and capsule counting
- Blister and strip packaging lines
- Cartoning, labelling and serialisation
- Dosing pumps
- Cosmetic powder pressing
- Cleanroom handling and inspection
What pharmaceutical machinery demands from motion
Pharmaceutical machines are high-speed packaging and process machines with three extra constraints. They have to be cleaned, sometimes with hot water and aggressive agents. They often have to contain potent powders. And the whole machine, including the software that moves the axes, has to be validated and kept in a validated state. A servo axis that is fast and accurate but cannot be wiped down, or whose drive firmware changes without notice, is the wrong axis for this industry.
The machine builder and the drug manufacturer own GMP compliance. Motion components contribute evidence: materials, sealing, safety functions and documentation. Get the evidence list agreed early, because it shapes the component choice as much as torque and speed do.
Where motion sits on a solid-dose and packaging line
| Machine | Main motions | Typical components |
|---|---|---|
| Rotary tablet press | Turret rotation, force feeder, fill depth, compression roll adjustment | AC servo or direct drive turret, servo feeders, absolute feedback |
| Capsule filler | Intermittent indexing, dosing discs or dosators, capsule separation and closing | Servo motors with cam profiles, linear actuators |
| Powder and auger filler | Auger rotation, container lift, nozzle movement | Servo motor on the auger, electric rod actuator on the lift |
| Liquid and volumetric filler | Piston strokes, nozzle dive, rotary turret | Hygienic rod actuators, slip ring and rotary union on rotary machines |
| Counting and inspection | Gates, fill station positioning, camera traverse | Belt or ballscrew linear modules, small steppers |
| Blister and cartoning | Forming, sealing, punching, carton feed | Multi-axis EtherCAT servo drives, planetary gearheads |
LinMot lists pharmaceutical uses from dosing to gripping and handling, and Kollmorgen covers the chain from formulation through tablet pressing and capsule filling to packaging. The pattern is the same everywhere: replace line shafts, cams and pneumatics with servo axes, so a format change becomes a recipe change.
How to size a tablet press turret drive
Output sets the turret speed. For a rotary press:
Tablets per hour = stations × turret rpm × 60 × compression points per revolution
KORSCH publishes its XT 600 double rotary press with 115 stations on die table segments, two main and two pre-compression stations, and a single-layer limit of 100 rpm. That gives 115 × 100 × 60 × 2 = 1,380,000 tablets per hour, which is exactly the maximum the brochure quotes. Bi-layer production is limited to 60 rpm, and pre- and main compression are each 60 kN or 100 kN.
What this means for the drive:
- Speed range. The turret runs slowly during set-up and cleaning and up to its rated rpm in production. Check torque at both ends, including breakaway with a full die table.
- Cyclic load. Each punch pair passing the compression rolls is a torque pulse. Ask the press designer for the torque profile per revolution and size on RMS torque, with peak capacity for the highest compression force.
- Stiffness and smoothness. Speed ripple shows up as dwell-time variation under the rolls. A direct drive or a low-backlash gearhead with a stiff coupling helps.
- Containment and cleaning. The XL 400 brochure offers a wash-in-place version for OEB 5 containment, below 0.1 µg/m³. Anything mounted inside such a machine must survive the wash.
Capsule filling and powder dosing
Capsule fillers are intermittent-motion machines, so the motion profile matters more than top speed. Syntegon publishes its GKF 2600 at 156,600 capsules per hour from 145 cycles per minute with 18 segment bores (145 × 60 × 18 = 156,600). That is a cycle of about 0.41 s, in which the machine indexes, doses by tamping pin, dosator or vacuum, closes and ejects. Every axis has to accelerate and settle within its share of that cycle.
Powder filling is a good example of where electric actuators pay off. Tolomatic describes a powder filler that moved its container lift from pneumatics to a servo-driven electric rod actuator, removing the trial-and-error adjustment that each container change used to need. On a pill-counting machine, three belt-driven rodless actuators in a gantry position the fill station, with strokes of about 950 mm and 495 mm.
Worked example: a volumetric filling actuator
Take a piston filler running 60 cycles per minute, with a 50 mm fill stroke done in 0.4 s and a 30 mm piston working against 3 bar.
- Speed. A triangular profile over 50 mm in 0.4 s peaks at 2 × 50 / 0.4 = 250 mm/s.
- Acceleration. 4 × 0.05 / 0.4² = 1.25 m/s², small enough that inertia barely adds to the load.
- Force. Piston area is about 707 mm², so 0.3 MPa × 707 mm² ≈ 212 N, plus seal friction. Take 300 N with margin.
- Duty. The axis moves every second, so it is close to 100% duty. Size on RMS force and check screw L10 life at about 14 million strokes a year (two 8-hour shifts, 250 days).
- Environment. If the filler is washed down, choose a hygienic stainless actuator such as the Tolomatic RSH or the integrated-motor IMA-S, both IP69K static.
These numbers are an illustration. Use the filler’s real product viscosity, back-pressure and cycle chart. Our linear actuator sizing guide covers the full method.
Cleanroom grades, washdown and containment
Know the room before you choose the part. EU GMP Annex 1 sets cleanroom grades for sterile manufacturing, and the revised Annex 1 entered into force on 25 August 2023 (one paragraph, 8.123, followed on 25 August 2024). Published limits for particles of 0.5 µm and larger:
| Grade | At rest (≥0.5 µm/m³) | In operation (≥0.5 µm/m³) | ISO equivalent |
|---|---|---|---|
| A | 3,520 | 3,520 | ISO 5 / ISO 5 |
| B | 3,520 | 352,000 | ISO 5 / ISO 7 |
| C | 352,000 | 3,520,000 | ISO 7 / ISO 8 |
| D | 3,520,000 | Set by the manufacturer from risk assessment | ISO 8 |
Annex 1 is written for sterile products, so tablets and capsules sit outside it, but solid-dose plants still run classified areas of their own. In every case, exposed ball screws, greased guides and brush slip rings shed particles. Fully sealed modules such as the LEC ballscrew and LBC belt actuators are built for dust-sensitive and cleanroom work.
For washdown, IP69K is the usual target. Under DIN 40050-9 it means 80 °C water at 80–100 bar and 14–16 l/min, sprayed from 100–150 mm at 0°, 30°, 60° and 90° for 30 seconds each. An IP rating says nothing about chemical resistance. Check 316 stainless, seal compounds, cable jackets and grease against the detergents and disinfectants on the cleaning schedule.
Validation and data integrity
The FDA’s 21 CFR Part 11 sets the criteria for treating electronic records and signatures as equivalent to paper. KORSCH, for example, describes its press HMI as Part 11 compliant. ISPE’s GAMP guidance takes a risk-based approach to computerised GxP systems. For motion components this means:
- Version control. Drive and controller firmware and parameter sets are configuration items. Ask for change notification and long-term availability.
- Backup and restore. A replacement drive must load the validated parameters without hand tuning.
- Records. The controller or HMI, not the drive, usually holds the audit trail. Make sure the fieldbus exposes what the batch record needs.
- Safety. Specify STO and any Safe Motion functions with their stated SIL or PL.
We stay at component level. Your quality and validation team decides what the machine must demonstrate.
Typical pitfalls
- Specifying IP69K and forgetting the chemicals. Seals and cable jackets fail before the housing does.
- Sizing on peak rpm alone. Tablet press and capsule filler axes are limited by cyclic torque and settling time.
- Asking for a “GMP motor”. Ask instead for materials certificates, food-grade lubricant data, change notification and documentation.
- Putting standard modules in a classified zone. Unsealed screws and belts become particle sources.
- Leaving firmware uncontrolled. A silent drive update can invalidate a qualified machine.
What to send us
List each axis with its motion, load, stroke or rotation, speed and duty, plus the machine output rate. Add the room grade or ISO class, the cleaning method and agents, any containment level, supply voltage, fieldbus and safety functions. Our specialist engineering and supply partners will propose matched motors, actuators and drives with the documentation your validation needs.
Servo motors for tablet presses and blister lines
AC servo motors drive tablet press turrets and feeders, capsule filler indexing, blister forming and sealing stations, and cartoner axes. Size them from the machine rate: turret rpm or cycles per minute set speed, and the compression, sealing or indexing load sets peak torque. Absolute multi-turn feedback avoids homing after a cleaning stop. In product zones ask for IP65 or IP67 sealing, smooth housings or a stainless cover, and cables and grease that survive the plant's cleaning agents. Motors outside the product zone, behind a wall or in a technical area, can be standard industrial frames, which saves cost and simplifies validation.
- Tablet press: turret and feeder drives
- Capsule filler: indexing and dosing station drives
- Blister line: forming, sealing and punching axes
- Cartoner: carton feed and pusher axes
- Counting line: conveyor and gate drives
Available through our supply network
All servo and stepper motors →Specify servo and stepper motors for pharmaceutical →
Hygienic actuators for powder filling and dosing
Electric rod actuators replace pneumatic cylinders on container lifts, dosing pistons, fill nozzles and diverters. Their stroke and speed are set in software, so a format change becomes a recipe change rather than a mechanical adjustment. For product-contact or washdown areas choose 316 stainless bodies with welded seams, IP69K static sealing, FDA-compliant seals and food-grade grease. Size from the peak force at the end of the dose, the cycle rate and the RMS duty, then check screw life. Planetary roller screws suit high-force pressing and long life; ball screws are the economic choice for lighter filling and lifting.
- Powder filler: container lift during the fill
- Volumetric filler: piston and nozzle drive
- Capsule and tablet lines: reject gates and diverters
- Cosmetic powder press: pressing head
- Liquid filling: dosing pump stroke
Available through our supply network
All linear actuators →Specify linear actuators for pharmaceutical →
Clean room linear actuators for handling and inspection
Belt and ballscrew linear modules move fill stations, pick heads and inspection cameras over counting, packing and inspection machines. In a classified room the module itself is a particle source, so choose fully sealed versions with strip covers or bellows, and ask for cleanroom grease and any particle test data the maker has. Specify stroke, payload, speed, repeatability and mounting orientation, and whether the axis is above open product. Belt drives give long, fast strokes; ballscrews give higher stiffness and finer positioning for vertical or loaded axes.
- Tablet counting: fill station gantry
- Visual inspection: camera and lighting traverse
- Cleanroom pick and place: tray and vial handling
- Laboratory scale filling: XYZ dosing head
Available through our supply network
All linear actuators →Specify linear actuators for pharmaceutical →
Slip rings for tablet press and rotary filler turrets
A slip ring is needed wherever power, sensor or fieldbus circuits must cross a continuously rotating turret: weigh cells or heaters on rotary fillers and cappers, sensors on rotating tables, or instrumentation that turns with the machine. Specify every circuit with its current, voltage and signal type, the bore needed for shafts or product lines, the speed and the IP rating for the cleaning regime. Washdown areas call for sealed IP65 to IP68 units with stainless or coated housings. If air or vacuum must cross the same axis, combine the slip ring with a rotary union in one assembly.
- Rotary filler and capper: power and load-cell signals to the turret
- Rotary tables: sensor and Ethernet links
- Rotating vacuum heads: air and vacuum through a rotary union
- Washdown packaging turrets: sealed power and signal
Available through our supply network
Direct drive motors for rotary indexing in pharma machines
Direct drive torque motors take out the gearbox and belts on rotary indexing tables, turrets and star wheels. That removes backlash, wear debris and lubricant from the drivetrain, and gives a large hollow centre for services. Specify the load inertia, the index angle and time, the settling accuracy and any process torque, then check the motor's continuous torque against the RMS of the index profile. Frameless kits build into the machine's own bearings and housing; housed direct drive motors arrive with bearings and an encoder and are quicker to integrate.
- Rotary indexing tables: vial and syringe handling
- Star wheels: container transfer
- Laboratory shakers and mixers: smooth low-speed rotation
- Rotary inspection stations: precise indexing
Available through our supply network
All frameless and torque motors →Specify frameless and torque motors for pharmaceutical →
Servo drives for GMP filling and packaging lines
No drive is GMP-compliant on its own: the finished machine and its validated control system are. What the drive brings is the evidence and functions the validation needs: firmware version control, parameter backup and restore, Safe Torque Off with a stated SIL or PL, and a fieldbus that lets the line controller log what each axis did. EtherCAT drives with absolute encoder support keep position through a power cycle. Multi-axis drives save cabinet space on blister and cartoning lines. Mount drives in a clean technical area and specify cable lengths and EMC filtering for the plant.
- Blister lines: multi-axis EtherCAT drives
- Capsule fillers: synchronised dosing and indexing
- Tablet presses: turret and feeder drives with STO
- Cartoners: electronic cam and gearing between axes
Available through our supply network
Stainless gearheads for washdown pharma machines
Where a servo axis needs reduction in a washdown or corrosive area, a stainless planetary gearhead with food-grade grease avoids painted housings that flake and lubricants that are unacceptable near product. Specify ratio, peak and nominal output torque, backlash class, IP rating and the cleaning agents in use. Outside the product zone, standard planetary gearheads with IP65 sealing are usually enough. Check the gearhead's thermal limit at the duty, because sealed gearheads in enclosed machines run warm, and confirm the input flange matches the servo motor you have chosen.
- Washdown conveyors and feeders: stainless gearheads
- Tablet press feeders: low-backlash reduction
- Cartoning and packing: right-angle gearheads in tight frames
Available through our supply network
All gearboxes and harmonic drives →Specify gearboxes and harmonic drives for pharmaceutical →
Motion controllers for validated pharma packaging
A CODESYS or IEC 61131-3 motion controller on EtherCAT coordinates filling, dosing, labelling and packing axes with electronic cams instead of mechanical line shafts. For a validated machine, look for version-controlled projects, user management, audit trail support in the HMI or supervisory layer, and stable firmware with long-term availability. Specify the number of axes, cycle time, I/O count and the protocols the line's MES or serialisation system uses, such as OPC UA. Ask how long the controller hardware and its programming tool will stay available, because requalifying a replacement is expensive.
- Filling lines: synchronised dosing and conveying
- Labelling and serialisation: registration and print triggers
- Blister lines: electronic cams between forming, sealing and punching
Available through our supply network
All controllers and plcs →Specify controllers and plcs for pharmaceutical →
Standards to have in view
- EU GMP Annex 1 (manufacture of sterile medicinal products; revised version in force 25 August 2023)
- ISO 14644-1 (cleanroom air cleanliness classes)
- 21 CFR Part 11 (FDA electronic records and electronic signatures)
- ISPE GAMP 5 Second Edition (risk-based approach to computerised GxP systems)
- IEC 60529 and ISO 20653 / DIN 40050-9 (IP codes, including IP69K)
- EN 60204-1 (electrical equipment of machines)
- ISO 13849-1 (safety-related parts of control systems)
- IEC 61800-5-2 (drive safety functions such as STO)
Which standards apply depends on the end product and its market. Your engineer will confirm what the component itself needs to meet.
Frequently asked questions
Which motors are used in a rotary tablet press?
Modern presses use servo or variable-speed motors for the turret, the force feeder and the fill-depth and compression-roll adjustments, with absolute feedback so settings are kept after a stop. The turret drive must hold speed under the cyclic load of every punch passing the compression rolls, which reach 60 kN or 100 kN on published high-speed presses. Motors near the product zone need sealing and finishes that survive cleaning.
Do servo drives need to be GMP certified?
There is no GMP certificate for a drive. GMP applies to the manufacturer and its validated process and equipment. The machine builder validates the complete control system, often following ISPE GAMP 5, and computerised records may need to meet 21 CFR Part 11 or EU GMP Annex 11. From the drive supplier you need version control, change notification, documented safety functions and parameter backup.
What IP rating does a pharmaceutical actuator need?
It depends on the cleaning. Dry-cleaned areas often accept IP54 or IP65. Areas washed with hoses or high-pressure cleaners call for IP69K, tested with 80 °C water at 80–100 bar from 100–150 mm. IP ratings say nothing about chemical resistance, so also confirm housing material, seals and grease against the plant's detergents and disinfectants.
Can electric actuators replace pneumatic cylinders on a powder filler?
Yes, and the main gain is changeover. Tolomatic describes a powder filler where an electric rod actuator took over the container lift, removing the trial-and-error pneumatic adjustment needed at each container change. The servo also gives a repeatable motion profile for even fills. Size it for the container mass, lift speed and cycle rate.
Are linear motors used for pharmaceutical dosing?
Tubular linear motors and short-stroke voice coils are used for fast, programmable dosing and handling moves, because they have no screw to wear and can vary stroke and force each cycle. For high-force pressing or long life under load, a servo-driven ball or roller screw actuator is usually the better fit. Clean design and cable routing matter more than the motor type.
What should I send for a pharma machine motion enquiry?
Send the machine type and output rate, each axis's stroke or rotation, load, speed and duty, and the cleanroom grade or ISO class of the area. Add the cleaning method and agents, the IP rating needed, any containment level, supply voltage, fieldbus, and the safety functions required. State which documents your validation needs from component suppliers.
Sources
- KORSCH: XT 600 high-speed double rotary press brochure
- KORSCH: XL 400 flexible technology brochure
- Syntegon: GKF 2600 capsule filling machine
- GMP Insiders: GMP cleanroom classifications, Grade A to D
- PIC/S: Entry into force of revised Annex 1
- ROLEC: IP69K test conditions (DIN 40050-9)
- 21 CFR 11.1: Scope (Legal Information Institute)
- ISPE: Guidance documents (GAMP)
- Tolomatic: Powder filling application
- Tolomatic: Automatic pill sorting for pharmaceutical filling (MEDSCI-009-E)
- Kollmorgen: Motion control solutions by industry
- LinMot: Industry solutions
Figures are summarised from the sources above and from manufacturers' published data on the date shown. Always confirm against the current datasheet for your exact part.