Method and apparatus for forming capsules

Apparatus for forming a pharmaceutical capsule containing a powdered material therein, said apparatus comprising:

• feeding means for feeding a capsule forming material having a cavity formed therein along a predetermined path, said capsule forming material forming a portion of the casing of the capsule;
• powder supply means containing a supply of powdered pharmaceutical material;
• a cylindrical punch roll having a radially extending chamber therein extending radially inward from an open end on the cylindrical surface of said cylindrical punch roll, said cylindrical punch roll being rotatably mounted adjacent said supply means to receive within said chamber a predetermined charge of powdered material from said supply means as said cylindrical punch roll rotates past said supply means, and said powder supply means and said cylindrical punch roll both being operatively isolated from said predetermined path along which said capsule forming material is fed;
• punch compacting means associated with said cylindrical punch roll, said punch compacting means including punch means for compacting said predetermined charge of powdered material in said chamber to form a compacted substantially solid slug as said cylindrical punch roll is rotated;
• a cylindrical transfer roll associated with said cylindrical punch roll for transferring said compacted substantially solid slug in said chamber of said punch roll into said cavity in said capsule forming material as said capsule forming material is fed along said predetermined path, said transfer roll having a recess in the cylindrical surface thereof and being rotatably mounted adjacent to said cylindrical punch roll and intermediate said cylindrical punch roll and said predetermined path along which said capsule forming material is fed, said transfer roll being operatively rotatable to align said recess therein with said chamber in said punch roll as said punch roll is rotated after said compacted substantially solid slug is formed in said chamber to receive said compacted substantially solid slug from said chamber into said recess and operatively rotatable to then deposit said compacted substantially solid slug in said recess into said cavity in said capsule forming material;
• said transfer roll having means associated therewith for collecting free and uncompacted powdered material transferred with said compacted substantially solid slug to said transfer roll to thereby minimize the depositing of free, excess powdered material onto said capsule forming material;
• and
• sealing means for sealing said cavity in said capsule forming material after it has received said compacted substantially solid slug.