In previous articles, we discussed nitrogen and filling accuracy. Today, we'll discuss another parameter of interest: production speed. We often hear of speeds of 50, 120, 180, or even 240 capsules per minute. But does this represent the machine's actual output per minute? Not quite. The nominal speed and actual production output are not entirely the same. Let's take a look.
1. What is the nominal speed of a coffee capsule filling machine?
The nominal speed usually refers to the operating speed that the equipment can achieve under specified conditions. For example, a four-channel rotary coffee capsule filling machine that runs 45 cycles per minute, completing 4 capsules per cycle, has a theoretical production speed of 180 capsules per minute. At this speed, the machine's theoretical output per hour is 10,800 capsules, and its theoretical output in 8 hours is 86,400 capsules.
Achieving this figure requires the machine to operate at its nominal speed continuously without any downtime, speed loss, or defective products. However, real-world production environments are prone to various issues, so actual production output is often lower than theoretical output.
2. Why is actual output usually lower than the nominal speed?
Firstly, it's affected by material supply. Coffee powder, empty capsules, and sealing film require continuous replenishment. If the automatic feeding system's capacity is insufficient, or if operators need to frequently stop to refill, production efficiency will be affected.
Secondly, there are daily equipment adjustments. For example, changing coffee types, adjusting filling weights, changing sealing materials, and cleaning the equipment all consume normal production time. Sometimes, abnormal capsule feeding, sealing film detection alarms, or unstable material supply may occur, necessitating a machine stoppage for inspection.
Furthermore, there's the issue of product quality. Even when the equipment runs at normal speed, issues such as incorrect filling weights or sealing problems may still occur. These products cannot be included in the output.
3. How to calculate the actual production output of coffee capsules?
The most common method is to estimate actual output based on the overall equipment efficiency. OEE primarily considers equipment availability, performance efficiency, and product quality pass rate. Simply put, it's how long the equipment actually runs within the planned production time, whether the operating speed meets expectations, and how many products ultimately meet quality requirements.
OEE = Availability × Performance Efficiency × Quality Pass Rate. For example, a coffee capsule filling machine with a nominal speed of 180 CPM, assuming an overall efficiency of 80%, would have an estimated qualified output of: 180 × 60 × 8 × 80% = **69,120 capsules** within an 8-hour planned production time. Below is a comparison of theoretical output and estimated actual output at different production speeds (for reference):
| Nominal Speed |
Theoretical Output in 8 Hours |
Estimated at 80% OEE |
| 50 CPM |
24,000 |
19,200 |
| 120 CPM |
57,600 |
46,080 |
| 180 CPM |
86,400 |
69,120 |
| 240 CPM |
115,200 |
92,160 |
It's important to note that the 80% OEE figure here is for demonstration purposes only and does not represent the efficiency of all coffee capsule filling machines. Actual production performance depends on factors such as equipment configuration, packaging materials, operating methods, and production management.
4. Is a faster production speed always better?
This is a one-sided understanding. When selecting equipment, the most important consideration is whether the spare capacity can match the actual production demand.
5. How to verify machine production speed in a Factory Acceptance Test (FAT)?
During the test, in addition to confirming the machine's production speed, it's crucial to continuously observe the equipment's stability during continuous operation.
The test should ensure that the coffee powder, capsules, and sealing materials are consistent with those used in actual production, and that the machine operates at the expected production speed. This provides a more accurate reflection of the equipment's performance on the target product. It is recommended to record equipment operating time, actual output, number of defective products, and downtime during the test to gain a more comprehensive understanding of the machine's performance.
6. How to select the appropriate equipment based on actual needs?
First, clearly define the target daily output and planned production time. For example, a coffee company plans to produce 60,000 capsules per day, scheduling 8 hours of production daily, and initially estimating an overall efficiency of 80%. Therefore, the required nominal speed of the equipment is approximately: 60,000 ÷ (8 × 60 × 80%) ≈ 156 CPM. This means you need to consider equipment with a nominal speed higher than 156 CPM, rather than choosing a machine with a nominal speed of 120 CPM.
It's important to note that if you anticipate continued order growth in the coming years, you should also allow for some reserve capacity to avoid situations where you cannot meet your capacity requirements in the short term.
In conclusion:
Now we understand why the nominal speed of a coffee capsule filling machine differs from its actual production speed, but the nominal speed remains an important parameter for measuring the equipment's production capacity. Therefore, rather than simply pursuing a higher CPM, it's more reasonable to choose the most suitable speed based on actual production conditions.
EXPAK Packaging has extensive experience and professionals in this area and welcomes your contact!
Publication Date: 10/15/2026
Category: Product Events
