precisioncount electronic tablet and capsule counting

PrecisionCount

High-Performance Electronic Counting System for Solid Dose Products

PrecisionCount represents the latest generation of high-accuracy, electronic tablet and capsule counting technology developed by Pharma Packaging Systems.

Overview and benefits

PrecisionCount Overview

PrecisionCount represents the latest generation of high-accuracy, electronic tablet and capsule counting technology developed by Pharma Packaging Systems. Built around our proven vibratory product feed design and the latest in microprocessor-based control, PrecisionCount delivers reliable, high-speed performance across a wide range of solid dose formats.

Each system is equipped with multiple vibratory feed trays that guide product from bulk hoppers into controlled streams for counting. The dual-stage vibratory feed system incorporates rear and front trays with V-shaped tracks designed to gently separate, orientate, and present product to the infrared counting sensors. A unique nib separation feature ensures stacked or doubled tablets are removed and re-circulated, enhancing count integrity and line efficiency.

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Dual Vibratory Tray System

Rear and front trays with V-shaped tracks for gentle separation and orientation

High-Speed IR Counting

Infrared sensors scanning 34,000 times per second.

Nib Separation Feature

Removes stacked or doubled tablets to enhance count integrity.

No Change Parts

Compatible with most tablets, capsules, and softgels.

Control and Configuration

The high-speed infrared sensors scan 34,000 times per second and feature onboard microprocessors that self-adjust to environmental changes and compensate for dust buildup. This removes the need for routine calibration and ensures optimal counting accuracy throughout the production run. All parameters are stored within the system’s memory and can be recalled instantly via a user-friendly touchscreen HMI.

PrecisionCount requires no change parts and can handle most product shapes and sizes with minimal setup. Product-specific settings can be configured manually or through an auto-learn feature, streamlining changeovers and reducing operator input.

Intelligent Discharge and Pre-Batching

Intelligent pneumatic pre-count gates allow flexible discharge strategies including full-count, track-specific, or staggered release to maximise efficiency. Integrated trap-boxes enable pre-batching, allowing the system to count continuously while waiting for downstream equipment, such as pouches or tubs, to be ready.

Integration and Maintenance Access

Full system integration includes handshake signalling with downstream machines to ensure reliable timing and transfer of product. Built in stainless steel, the PrecisionCount system offers full access to the electrical panels and servo drives through large cabinet doors for easy maintenance.

Hardware Counters

Custom Solutions Across Multiple Product Types

Over the years, PPS has successfully delivered a wide range of specialised counting solutions for non-pharmaceutical products, including chocolate pieces, dishwasher pods, hardware items such as nuts and bolts, and general confectionery. These projects have required adaptations in feed systems, sensor configurations, material handling, and hygienic design, all while maintaining high levels of counting accuracy and throughput.

We routinely accommodate complex container handling requirements, oversized or irregularly shaped products, and high-output expectations. Depending on the project scope, machines can include multiple lanes, rotary platforms, integrated rejection systems, and downstream automation such as sachet, capping, labelling, and case packing. Vision inspection, metal detection, and data capture for traceability can also be incorporated as part of a turnkey system.

Chocolate

Pods

Hardware

Confectionery

Engineered for High-Accuracy Solid Dose Counting

Applications and Features

PrecisionCount is designed for demanding solid dose production environments where accuracy and consistent throughput are critical. Its no change parts design and flexible discharge strategies support a wide range of product shapes and sizes, while intelligent pre-count gating and trap-box batching enable continuous operation. Full handshake signalling ensures reliable timing and product transfer within integrated packaging lines.

No change parts

Compatible with most tablets, capsules, and softgels

Dual vibratory tray system

For precise feed and orientation

High-speed IR sensors

With auto-adjust and learn functionality

Intelligent gating

And pre-batch trap-boxes for maximum speed

Reliable downstream signalling

For consistent handoff

Nib separation feature

Removes stacked or doubled tablets

Integrated dust extraction

And product re-circulation

Touchscreen Interface

With product memory and access levels

Stainless-steel construction

And fully cGMP compliant

Full validation documentation available

Installation and Operational Qualifications

Downloads

Brochures, Datasheets & Technical Documentation

Access our latest product literature, specifications, and validation documents — available on request.

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