Choosing a high-performance pill press machine can be an overwhelming task.
A reason why this guide will explore all the fundamental aspects of the pill press machine such as design, parts, working principle, quality compliance and tooling options, just to mention a few.
So, if you want to be an expert in pill press machine, read this guide.
- What is a Pill Press Machine?
- Is Pill Press Machine the same as Pill Maker?
- What are the Applications of Pill Press Machine?
- What are the Parts and Components of Pill Press Machine?
- What is the Working Principle of a Pill Press Machine?
- How many types of Pill Press Machines are there?
- What are the Design Features of a Pill Press Machine?
- What are the Press Options of Pill Press Machine?
- Is there a Difference between Pill Press Machine and Tablet Press Machine?
- What is the Cost of a Pill Press Machine?
- Why is cGMP Compliance important for Pill Press Machine?
- What are the additional Compliance Requirements for Pill Press Machines?
- Can a Pill Press Machine Design affect the Tablet Performance Characteristics?
- What Sizes and Shapes of Pills can I make using a Pill Press Machine?
- Can I make Engraved Pills using a Pill Press Machine?
- How many Pills can a Pill Press Machine Generate per Hour?
- What is the Maximum Weight of a Pill that can be Made on Pill Press Machine?
- How do you Determine the Right Pill Press for Your Production Facility?
- How can you choose the Right Tooling Systems for your Pill Press Machines?
- Are there Standards for Pill Press Machine Tooling System?
- How do I install Tooling and set up a Pill Press Machine?
- What is a Tooling Inspection and Analysis System for Pill Press Machine?
- Why should I get a Tooling Inspection and Analysis System for my Pill Press Machine?
- What is a Dust Cup Puncher, and is it necessary for Pill Press Machine?
- What is Pill Press Auto Weight?
- How does Auto Weight Control work for Pill Press Machine?
- What are the main Features of Pill Press Machines with Auto Weight Control?
- How do I Trouble Shoot Pill Press Machine?
- How Frequently will you Replace Pill Press Machine Parts?
- Do I get Die with a Pill Press Machine, or do I have to Buy it Separately?
- Which is the Best Material for Pill Press Machine Contact Parts?
- What Material is the Outer Casing of a Pill Press Machine made of?
- Are there any Active Ingredients that Interact or are Affected by anything in a Pill Press Machine?
- What is Maximum Compression Force for Pill Press Machines?
- Are there any Products that Pill Press Machine cannot Press due to Maximum Compression Force?
- What Safety Features do Pill Press Machines come with?
- Is the Tooling for all Pill Press Machines the same?
- Is it easy to change the Tooling for Pill Press Machines?
- How Fast do Tooling for Pill Press Machines Wear Out and Break?
- Can I get Custom Tooling for my Pill Press Machine?
- Do I need a License to own a Pill Press Machine?
- How do I keep my Pill Press Machine Clean?
- Do Pill Press Machines come Fully Assembled?
- How is the Durability of Pill Press Machine in Comparison to other Pharmaceutical Press Machines?
- How many Operators do I need for Pill Press Machine?
- What is the Power Consumption of Pill Press Machines?
- What is the Warranty for Pill Press Machines?
What is a Pill Press Machine?
Pill press machine
The pill press machine is a mechanical contraption you employ in converting powder into pills via a compression process.
You can have pills in different shapes and sizes in addition to weight, depending on your tooling system.
The pill press machine is an important piece of equipment in our lives as it enables the dispensation of drugs.
Providing such drugs in pill form allows easier consumption of drugs for whatever purpose, such as medicinal or cosmetic use.
The increased demand for drugs has allowed more efficient pill press machines to cater to the increasing needs.
Technologies you find commonly applied in pill press machines include the use of electric-driven motors and compression tech.
Is Pill Press Machine the same as Pill Maker?
All pill press machines are pill makers but not every pill maker is a pill press machine.
The term pill maker is a general terminology you use to refer to any contraption geared towards making pills.
You can use several methods to make pills, one of which is compressing powder using a pill press machine.
Other approaches to making pills include filling capsules and using mold plates.
With a pill press machine, you particularly employ compression force to produce a tablet of the desired shape and size.
With capsule pills, you make them by enclosing powder material in specially fabricated containments.
What are the Applications of Pill Press Machine?
You find pill press machines useful in the making of pills across various industries to meet specific use.
Some common application of the pill press machine include:
- A manual pill press machine allows you to make pills for research and development in laboratories.
In this instance, you make tablets in small quantities to fit your research purpose and development goals.
- You use the pill press machine in the large-scale production of drugs for pharmaceutical use.
You can achieve the production of drugs in different sizes, shapes, and weights using the pill press machine.
- Pill press machines help you produce chewable pills used as supplements for health purposes in the nutraceutical industry.
These pills contain active ingredients that provide a boost to your body’s nutrients, such as vitamins and proteins.
- The pill press machine is also useful in the making of effervescent employed in a variety of applications.
Effervescent contains certain acidic strains that exhibit an effervescence effect when combined with water.
- The pill press machine also allows you to formulate pills for the cosmetic industry. Such pills are used for purposes such as skin lightening and clearing.
What are the Parts and Components of Pill Press Machine?
Pill press machine
The pill press machine is a contraption you find with different parts and components essential to its proper working.
Some of the major parts of the pill press machine include:
- The bottom plate and machine base.
- A pair of stands and frames for the front and rear.
- A worm gearbox.
- A control cabinet.
- A support block for the upper section.
- A punch plate construction.
The fixed frame of a pill press machine encompasses the frame and stand pairing alongside the bottom plate affixed with bolts.
Additionally, the gearbox and machine base fixed together to complete the pill press machine’s fixed frame structure.
Some of the components attached to the gearbox at the base of the pill press machine include:
- The mechanism for filling and metering material.
- A protection device for the lower punch system.
- The bottom pre-compression roller.
- The main control of the main compression roller.
- The guard rail system including that for discharging tablets, filling, and protecting lower punches.
- The disassembly for the die system.
You also find the punch plate and the upper guide rail system connected via supporting blocks.
These blocks are fortified by column rods on the left and right, providing formidable anti-bending and torsion.
You find this build allows the press pill machine to withstand the loading needs when operating at high speeds.
The upper section also has a guide rail plate and rollers for the top pre and main compression.
Furthermore, you have Perspex doors for the upper section’s sides furnished with telescopic springs for accommodating tension.
The closed-off upper section contains the tooling system alongside the force feeder and deduster.
An airtight seal is used for the compression chamber to thwart the contamination of the pill-making process.
The lower section contains the lubricating and transmission systems with the automatic control appliance sealed to prevent dust entry.
What is the Working Principle of a Pill Press Machine?
Pill manufacturing process
While there are different pill press machines you can use, their principle of working is similar.
You can have a manual pill press machine suitable for low production needs and an automatic one for higher production.
Furthermore, you will find automatic pill press machines provided with a single tooling station or multiple stations on a rotating platform.
The choice of oil press machine is subject to several factors, including cost.
Using a manual pill press machine is simpler as it only involves a single tooling kit.
Furthermore, controlling the pill-making process is less complex on a single press machine.
In a pill press machine with a single tooling kit, you have a die with a top and bottom punch pairing.
Contrarily, the automatic press with multiple stations has several punches rotating around a die table.
As the turret rotates, the multiple punch parings move vertically over the die, compressing the powder.
A cam system controls the compression process with settings ensuring the pills have similar weight and form.
During the pill-making process, the powder is delivered into the die bore before the punches exert a force binding the material.
The lower punch supports the die’s material, while the top punch provides the force for compaction.
Consequently, you find the tablet’s depth, and subsequently, the lower punch position determines weight.
By its position, it regulates the amount of powder contained in the die cavity.
Powder in excess at the top is trimmed off before the force exertion by the top punch.
The force binds together the powder or granules into a solid pill before it is ejected by raising the lower punch.
How many types of Pill Press Machines are there?
The pill press machine is available in several configurations as follows:
· Manual Pill Press Machine
Manual pill press machine
The manual pill press machine utilizes human effort in the pill-making process.
A human operator feeds the powder or granulated material into the hopper while also applying the compression force.
The manual pill press machine features a single tooling station you use to produce one pill for each compression operation.
Consequently, the manual pill press machine is suitable only for small production volumes.
You can employ the manual pill press machine in a laboratory for your research needs.
A manual pill press is also helpful where you have periodic demands of pills in small quantities.
· Pill Press Machine Automatic
Automatic pill press
The automatic pill press machine employs a Programmable Logic Controller (PLC) for all the processes involved with very little human input.
The PLC guides the feeding process and the compression process ensuring the process is highly efficient and precise.
The pill-making process using an automatic pill press machine is fast and consistent devoid of human limitations such as exhaustion.
Accordingly, you can meet large production needs with this type of pill press machine.
Automatic pill press machines can have multiple tooling stations allowing you to further multiply your production capacity.
A rotating two-part component called a turret holds multiple punches on both sides of a die table.
Such an automatic pill press can help you achieve very high pill production per minute and is effective for commercial use.
Furthermore, you can adjust the functionality of the machine via a control panel that programs the controller.
· Semi-automatic Pill Press Machine
A semi-automatic pill press machine encompasses both programmed control and human control in its functions.
For instance, you can manually feed material to the hopper while the compression process is automated via a PLC.
A semi-automatic machine is a bargain when you want to work on larger production volumes but short on financing.
The semi-automatic pill press costs less than a fully automatic pill press machine with the same production capability.
What are the Design Features of a Pill Press Machine?
A pill press machine entails certain design features allowing you to make pills of a determined size, shape, and weight.
The design features of your pill press machine influence the characteristics of your pills.
Some of the significant design features you consider for a pill press machine include:
Pill press tooling system
· The Tooling Design
Your pill press machine’s tooling design influences the physical and chemical characteristics of the pills you produce.
Therefore, you need to have the appropriate tooling design to make pills with the desired shape and size.
Standardization of the tooling allows you to make tooling changes more easily without increasing costs.
You have two standards at your disposal: Tablet Specification Manual (TSM) and Euro Standard (EU).
Using standards allows you to make tooling changes to produce pills with different sizes and shapes intermittently.
However, you observe these changes do not involve extra costs for the pill press machine’s operation.
· Punch System
The punch system of the pill press machine dictates the effectiveness of the compression process.
The punch system needs to be resilient and reliable to ensure the appropriate pills are produced.
The head radius and head flat are two important aspects of the punches that define the pill-making process.
When you vary these two aspects, you influence the compression process profile and the required time of contact.
· The Die Shape
The die influences your pills’ shape and size as its cavity contains the powder or granules during the compression process.
You can use different profiles for your die, including round and non-round while accommodating the simplest to the most intricate design.
What are the Press Options of Pill Press Machine?
When using a pill press machine, you can have a single station press or a multi-station press.
The difference between these press options lies in the number of tooling stations the machine has.
· Single Station Press
The single punch press machine has only one tooling station consisting of a punch pair and die.
The punch pair is separated by the die, creating a lower/bottom and upper/top punch.
You can manually control the vertical movement of the punches or employ an electric motor to increase efficiency.
While operating the single punch press, you observe the pill-making process is enabled by the top punch movement only.
The bottom punch regulates the amount of powder material in the bore and remains stationary during the compression process.
However, you initiate an upward movement of the bottom punch to eject the pill upon completing the process.
· Multi-station Press
The multi-station press has more than one tooling station with several punch pairings and a die table.
The punch pairings are held in place by a turret above and below the die table, holding the top and bottom punches, respectively.
The turret rotates around the die table containing several dies for the compression of multiple pills.
Cam tracks control the movement of the punches initiating the pre and main compression process alongside ejection.
The punch pairings typically match the die count on the die table, capable of rotary motion.
The top punches are typically used in the compression process, whereas the bottom punches are used in the ejection process.
Is there a Difference between Pill Press Machine and Tablet Press Machine?
The pill press machine and the tablet press machine share the same working principle regarding the compression process.
However, the tablet press machine is limited to making tablets in desired shapes and forms.
You can use the pill press machine to make a varied range of pills, including tablets.
You can also make pills in the form of gelatins and mints using a pill press machine.
What is the Cost of a Pill Press Machine?
There are different types, models, and configurations of pill press machines available in the market.
These machines have different automation and technical specifications, which influence the amount you pay for the machine.
For instance, you have the option of purchasing a manual press machine, semi-automatic, or fully automatic pill press machine.
A manual press machine costs you less than a semi-automatic machine which costs less than a fully automatic machine.
Furthermore, your pill press machine can have a single tooling station or multiple tooling stations regardless of the automation level.
Pill press machines with multi-station cost more than those with single stations due to their increased production capacity.
Additionally, you can find improvements made on pill press machines with the same features to enhance their efficiency, influencing their cost.
Such improvements can result in, say, lower power consumption, faster turret speeds, and increased options for the compression force.
However, given the technical disparities, you find pill press machines have a wide cost variance on the overall scale.
A pill press machine can cost from a few thousand dollars to hundreds of thousands of dollars.
Why is cGMP Compliance important for Pill Press Machine?
cGMP stands for Current Good Manufacturing Practices, a certification determined for manufactured goods such as the pill press machine.
cGMP ensures that the pill press machine’s manufacturing processes are up to accepted standards and safe for use.
Complying with cGMP alludes to the use of safe raw materials in the manufacture of the pill press machine.
Consequently, this machine’s subsequent use is not be endangered by its constitution, and neither is the process hampered by it.
Do Pill Press Machines Require FDA Approval?
Yes, they do.
The Food and Drug Administration (FDA) is an agency that seeks to safeguard public health by regulating food and drug substances.
Regulation of food and drugs is determined by supervising the production process and handling.
The pill press machine is employed in making pills for pharmaceutical and nutraceutical use for human consumption.
Consequently, pill press machines’ approval is necessary to ensure they’re capable of making such pills to the expected standards.
What are the additional Compliance Requirements for Pill Press Machines?
You find the following additional compliance requirements for the pill press machines:
· ISO Standard
The international Standards Organization sets standards across various fields, including manufacturing.
When manufacturing pill press machines, manufacturers ensure they adhere to the requisite standards set to achieve certification.
· Factory Acceptance Testing
FAT ensures the pill press machine developed by the manufacturer meets its functional design parameters.
Testing the pill press machine is done at the factory to verify that the equipment works appropriately without discrepancies.
· Installation and Operational Qualification
Installation Qualification ensures the pill press machine is securely fixed at the plant site without any missing parts or components.
Operational qualification confirms that the pill press machine responds as is expected upon being powered up.
Can a Pill Press Machine Design affect the Tablet Performance Characteristics?
When making tablets using a pill press machine, you can produce tablets in different shapes and sizes.
The shape and form of your pill or tablet determine the tooling system’s design with a direct complexity relationship.
Furthermore, the design of your pill press machine affects the tablet’s eventual performance in aspects such as swallowing.
For instance, overly large tablets not easily broken pose great difficulty and discomfort during swallowing.
Additionally, your tooling system has to be well maintained and set to prevent the making of pills susceptible to defects.
Common defects your pills can have as a result include erosion, cracking, sticking, and lamination.
Defective pills mean that you interfere with the composition and content matter of excipients in the tablet.
Consequently, when subscribed as medicine, the drug has a lower dosage resulting in ineffective treatment.
What Sizes and Shapes of Pills can I make using a Pill Press Machine?
You can make pills in different sizes and shapes using the pill press machine.
The tooling kit design of your pill press machine determines the pill size and shape.
The die cavity and head radius of your punch influence the size and shape of your pill.
You can have different shapes for your pill ranging from round to non-round shapes.
Common shapes you find the pill press machine capable of producing include: round, convex, and oval.
You can also make tablets in the form of rings and also with double layers using a pill press machine.
Common shapes of pills
Can I make Engraved Pills using a Pill Press Machine?
Yes, you can.
Engraved pills feature unique designs on their surfaces that can be trademarked for the manufacturing company or informational.
You use the head flat of the top punch to engrave pills during the compression process.
When tooling the pill press machine, you imprint your desired design on the punch’s head flat.
You mirror the design like that of a rubber stamp impressing upon the powder during the compression process.
How many Pills can a Pill Press Machine Generate per Hour?
The output of a pill press machine varies with automation and the number of tooling stations.
When using a single punch pill press machine, expect a lower output than a multi-station pill press machine.
Additionally, you have a low output using a manual pill press machine compared to an automatic pill press machine.
Furthermore, the size of the machine also determines the output, with large-scale machines besting small-scale machines.
Nonetheless, you will find pill press machines with the capacity to produce millions of pills in an hour.
Such machines find use in the large-scale production of highly prescribed drugs such as painkillers and antibiotics.
What is the Maximum Weight of a Pill that can be Made on Pill Press Machine?
Pills made by the pill press machine are commonly employed for pharmaceutical and nutraceutical purposes.
In making these pills, the punch and die system compresses the powder material of the desired concentration.
Several factors will influence the weight of the pill made by this machine, such as the excipient concentration.
Additionally, the die capacity also determines the pill’s weight with a small volume resulting in a small weight.
Besides, the formulation of your powder affects the weight of the pill, considering the material structure.
For instance, you will have heavier tablets using dense and coarse powder material.
Contrarily, using a light and soft powder results in a lighter pill.
You can determine the weight by establishing the bulk density of the powder fed into the tooling kit.
How do you Determine the Right Pill Press for Your Production Facility?
Several factors guide your selection when purchasing a pill press machine, ensuring the machine is ideal for your needs.
Some of the factors that help you determine the right machine include:
· Your Estimated Output Needs
Many different pill press machines are available with different outputs ranging from low output to medium output to high output.
Knowing how many pills you want to produce helps you select an appropriate machine for your facility.
· Size of Your Plant
While the pill press machine comes in different sizes and builds, you employ it alongside other machines and equipment.
Some of these machines and equipment include the mixing chamber, driers, and packaging equipment.
When purchasing a pill press machine, you have to consider your space needs to ensure all the equipment fit.
You can choose different configurations to effectively utilize your space requirements.
How can you choose the Right Tooling Systems for your Pill Press Machines?
The tooling system of a pill press machine encompasses the dies and punches.
These components allow you to determine the shape and size of the pill and, generally, its nature.
Choosing the right tooling system depends on various factors:
· Production Capacity
Your expected production capacity influences the tooling system you select.
Single punch press machines require a single tooling system and are useful where you have small outputs.
Alternatively, you can select a multi-station press machine that allows you to produce more pills per minute.
The multi-station press has multiple tooling kits with a punch and dies system held by a two-part component called the turret.
· Pill Form and Design
The shape and size of the pills are significant characteristics you consider when selecting the tooling system.
You achieve a desired shape and size by employing a tooling system that incorporates the shape and size in its design.
· Required Compression Force
When making a pill, the top punch exerts a force on the powder in the die bore during a compression process.
Your cooling system should be strong enough to sustain the compression process without damage.
· Powder Material
The powder material you compress when making pills constitutes the desired excipients for a particular dosage form.
Some materials possess abrasive and corrosive characteristics that can deteriorate the tolling system.
When choosing a tooling system, it is useful to identify the chemical properties of your powder material.
Consequently, you can ensure the materials used for your punches and die highly durable and not susceptible to such deterioration.
· Frequency of Use
The tooling system is susceptible to wear and tear over time due to the pill-making process’s nature.
When selecting a tooling system, you must know how frequently you intend to use the machine.
Frequent use requires you to select a highly durable and strong tooling system to sustain the wear conditions.
Therefore, the tooling system’s material should have impressive physical properties such as strength and rigidity.
Are there Standards for Pill Press Machine Tooling System?
Yes, there are.
There are two standards you consider when selecting the tooling system for your pill press machine.
These standards differ in dimension while sharing many configuration aspects with four classifications of B, D, BB, and DB.
The two standards are:
- The Tablet Specification Manual (TSM), which is an American standard, and
- The Euro Standard finds popular use in the European continent.
Some of the differences between the TSM and EU are as follows:
- Top profile in TSM is angled while that in EU is domed.
- Length of the punch in TSM is shorter than that of the EU.
- Inside head angle for the TSM in the ‘B’ classification is 37o, while that of the EU is 30o.
- The EU has a smaller head thickness than the TSM for both ‘B’ and ‘D’ classifications.
How do I install Tooling and set up a Pill Press Machine?
When installing a tooling system during machine set-up, you consider three important aspects.
These are the depth of fill, the applied punch pressure, and the ejection height.
You adjust your fill by altering the cog at the bottom of your machine within the lower assembly.
The cog at the top half of the assembly, on the other hand, determines the height of pill ejection.
You control the punch pressure by altering the drift pin in the upper assembly.
Besides, you require tools such as an allen key and a screwdriver to successfully install a tooling system.
You regulate the ejection height by moving the cog upwards or downwards by turning the cog clockwise or anticlockwise.
The lower cog that adjusts the bottom punch allows you to regulate the weight of the pill.
It does this by determining the amount of material allowed inside the bore of the die.
Moving the pin downwards increases the material and thus weight by tuning the cog clockwise.
Note that the amount of material will determine the punch pressure you need to execute the compression process.
Adjusting the drift pin in the top half of the assembly allows you to increase the pressure by moving it clockwise.
What is a Tooling Inspection and Analysis System for Pill Press Machine?
The Tooling Inspection and Analysis System of a pill press is an automated process that measures and documents the press tooling.
You employ the TIAS instead of manually determining the tooling measures, which is draining, costly, and time-consuming.
When you use TIAS, you achieve electronic recording of the inspection results to maintain database history.
Consequently, you can make conclusions and projections for your tooling needs and demands by comparing past measurements.
The downtime experienced in pill press machines is greatly reduced by the capability to point out worn-out tooling.
Thus, you can effectively manage and monitor your tooling kit.
Why should I get a Tooling Inspection and Analysis System for my Pill Press Machine?
There are several benefits you accrue by employing TIAS for your pill press machine. Some of these benefits include:
- Simplified process of obtaining tooling measurements
- Logging previous measurements taken by the TIAS allows you to make comparisons.
- You can accurately audit previous tooling measurements.
- The tooling selection process and set-up are optimized with the TIAS.
- You benefit from an improved quality assurance with a TIAS.
- A TIAS helps you achieve tighter inventory control.
- The operation process using a TIAS is streamlined.
- The planning process troubleshooting and design are improved with a TIAS.
What is a Dust Cup Puncher, and is it necessary for Pill Press Machine?
A dust cup puncher allows you to reduce the set-up time of the press while ensuring your dust cup fits perfectly.
A dust cup prevents entry of foreign matter such as grease into the powder material, leading to contamination.
When you use a dust cup puncher, it reduces the complexity of inserting dust cups.
Furthermore, it’s much safer to use the dust cup puncher as an operator as you can punch these cups off-line.
You find the dust cup puncher necessary for the pill press machine for the following reasons:
- With a puncher, you can accurately punch dust cups continuously.
- Using a dust puncher provides a better fit for your dust cups.
- You get a faster set-up for your press machine using a dust cup puncher.
- Using a dust cup puncher isolates the operator making it safer.
What is Pill Press Auto Weight?
Auto weight in pill press machine is an operation that uses automated means to determine the desired weight of the pill.
The principle of hydraulic pressure transmitted through a static fluid is the major enabler of auto weight in pill press machines.
How does Auto Weight Control work for Pill Press Machine?
You can determine the differences in the weight of tablets and control them by adjusting the compression force.
You use a strain gauge to identify through sensing mechanism any changes in the compression force.
The compression force changes as a result of a fluctuation of the weight of the pills.
You can attribute the fluctuation to the inconsistencies prevalent during the blending process of the powder material.
Weight changes in pills are consistent such that they will increase or decrease over the required weight.
You need a larger compression force when the weight of pills increases and a smaller force when it decreases.
A strain gauge captures the changes in the compression force applied during the pill-making process.
Consequently, the strain gauge communicates with the weight adjustment to respond by adjusting the fill level.
You discover a loop is created this way where the compression force influences the determination of the pill weight.
Therefore, you set up control measures to intervene in the reported weight differences by making necessary adjustments.
What are the main Features of Pill Press Machines with Auto Weight Control?
You find the following features present in pill press machines with auto weight control:
Pill press machine
· Machine Hopper
The pill press machine’s hoppers with auto weight control employ optimal flow angles to ease the flow process.
You find this especially useful where adjusting the powder formulation is virtually impossible.
Furthermore, some pill press machines with auto weight control have vibratory rods.
These rods improve the flow of material while reducing the chances of material separation.
· Feeder System
The feeder system in pill press machines with auto weight control consists of housing and peddles.
The housing consists of a special stainless steel material on which material cannot stick, preventing inconsistencies in volume during feeding.
Conversely, the feed peddles allow accurate and consistent powder measures into the die bore even at elevated speeds.
Otherwise, the absence of feed peddles results in inconsistent deliveries into the cavity leading to tablets with different weights.
· Press Punches
You use high-quality material for the press punches in machines with auto weight control to prevent wear.
Additionally, you coat these punches with a specially fabricated coating to avert sticking, leading to tablet defects.
· Press Die System
The die system of a press machine with auto weight control has defined edges to offer a neat impression upon punching.
Besides, it also features protection from corrosion with treatment making it non-stick.
Such a die system also features tapered angles that prevent air entrapment, allowing escape.
Consequently, you require a reduced force to eject the tablet while minimizing heat build-up via friction.
· Cam Tracks
Cam tracks ensure the pill-making process is seamless by guiding the top and bottom punches.
Therefore, you find cam tracks influential in enabling the filling process, compression, and pill ejection.
The cam tracks control the filling process and ejection by moving the bottom punch upwards and downwards.
Similarly, they control the pill’s compression process by moving the top punch downwards into the cavity.
How do I Trouble Shoot Pill Press Machine?
You can encounter various troubles with the pill press machine, each requiring a unique approach in solving.
The following are some of the issues you can encounter with your machine and how you can mitigate them:
· Unsmooth Pills
An unsmooth tablet can have pits or pocks with an undesired cover exceeding the tablet boundary.
Such a tablet results from using a rough punch surface or using inadequate procedures during mixing and blending.
Concerning this defect, you can replace the punch or smoothen it to the desired standard.
Additionally, you need to ensure you follow the right procedures using the required measures in preparing the material.
· Varying Punch Lengths
Having varied punch lengths requires you to always carry out retooling on punch sets simultaneously.
Also, you have to store sets of punch with similar qualities such as length and thickness.
· Abnormal Vibration
You can experience abnormal variation when you have loose joints and flexible screws.
Parts of the press machine can also be under heavy wear and tear or moving parts devoid of lubrication.
You mitigate this anomaly by inspecting the pill press machine regularly to identify worn-out parts and replace them.
Practicing routine maintenance involving lubrication of movable parts to reduce friction-induced noise wear also helps.
· Sticking on Punches
The issue with a sticking lower punch requires you to practice a frequent cleaning schedule for the punches and sockets.
Additionally, you have to regularly check the punch tips for any material accumulation.
· Scraper Wear
Sometimes, the scraper’s edge wears out, which requires replacing the edge with a new one.
You can also replace the while scraper instead rather than redress.
· Insufficient Material in Die
You remedy the situation by raising the chute for the feeder allowing more flow of material.
You can also eliminate large particles of materials that could be present and blocking the movement of material.
You can also increase the paddlewheel feeder’s speed by raising the pin grid feeder’s gate.
· Material Spillage into the Die
When this happens, you can employ the following measures:
- You can reduce the paddle wheel feeder speed or lower the feeder’s pin grid gate.
- A bent feed frame can also cause this defect requiring a re-leveling.
- You can control the movement of the material by lowering the feed chute.
How Frequently will you Replace Pill Press Machine Parts?
Replacing parts of the pill press machine is a process that considers the parts’ rate of wear and tear.
The parts’ wear and tear are dependent on the number of operations handled or the frequency of use.
Providing a fixed timeline for when to replace parts of your press machine is difficult.
However, you need to regularly inspect your machine and carry out maintenance to stave off wear and tear’s adverse effects.
Furthermore, replacing parts is costly, but you can carry out repairs where you have parts with extraneous damage.
Contrarily, excessive damage requires part replacement to allow for a consistent functionality level of the machine.
Do I get Die with a Pill Press Machine, or do I have to Buy it Separately?
Yes, you do.
When you purchase a pill press machine, it comes with a tooling system that encompasses a die and punches.
You can also customize the design of your tooling kit by providing the manufacturer with a list of particulars.
Customizing usually takes a while allowing the manufacturer to manifest your ideas and evaluate their applicability.
You can engrave information and emblems on your pills by including them in the tooling design.
Which is the Best Material for Pill Press Machine Contact Parts?
Contact parts in a pill press machine should adhere to the industrial standards that provide for their quality and durability.
These parts should be capable of tolerating the harsh conditions of wear and tear for a decent period.
The pill press machine’s contact parts include the die system and punches where the compression process is done.
The material used for pill press machines’ contact parts should be strong and durable with superior resistance to wear.
Some of the materials used for pill press machine contact parts include:
- Tungsten carbide
- High chrome steel, and
- High carbon steel
What Material is the Outer Casing of a Pill Press Machine made of?
The outer casing of a pill press machine protects the machine’s delicate parts from physical and chemical infraction.
You also find this casing useful in keeping out dust and other contaminants that can hamper the pill-making process.
You find different materials used to construct the casing of a pill press machine, such as aluminium and ceramic-based material.
Reinforced plastic also features in some casings of pill press machines, while others even use stainless steel.
Are there any Active Ingredients that Interact or are Affected by anything in a Pill Press Machine?
You find many pill press machines are tolerant to the active ingredients employed in materials for making pills.
However, you can carry out a material test to establish whether the machine is affected or affects the material composition.
Many pill press machines constitute stainless steel known to possess high resistant qualities to corrosion and decomposition.
Consequently, the material composition is hardly affected, and neither does it influence the material properties.
What is Maximum Compression Force for Pill Press Machines?
During the pill-making process, you find four forces involved: compression, friction, distributional, and radial force.
You have frictional force occurring between the material particles and the walls of the die.
The distribution force and the compaction force illustrate the compression force you apply during the pill-making process.
During the compression process, a force is applied to the top punch and transferred to the bottom punch.
However, the force attributed to friction between the particles and the die wall is lost during the pill-making process.
Consequently, the maximum compression force achievable is the summation of the friction force distributed to the lower punch.
Are there any Products that Pill Press Machine cannot Press due to Maximum Compression Force?
You will find pill press machines with different capabilities and technical specifications, allowing you to make different tablets.
Some machines achieve only a few pounds per square inch when applying compression force.
However, you find machines capable of thousands of pounds per square inch in compression force depending on the material and pill size.
Consequently, it is unlikely you find a pill press machine incapable of compressing a particular powder into the solid dosage.
What Safety Features do Pill Press Machines come with?
Safety features of a pill press machine ensure you are protected as a user when operating the pill press machine.
Furthermore, pill press machines have safety features to conform to the set industrial standards.
Some of the common safety features you find on a pill press machine include:
- An upper guard that is interlocked alongside a protection folio for overload relay.
- A mechanism for releasing overload pressure
- A stop button for emergencies.
Is the Tooling for all Pill Press Machines the same?
All pill press machines have the same tooling components, which include dies and punches.
The die and lower punch hold the material as the top punch applies the pill-making process’s compression force.
However, you have different tooling designs for pill press machines according to your pill’s shape and size.
You can also modify your tooling system to engrave information such as logos on pills.
Is it easy to change the Tooling for Pill Press Machines?
The ease of changing the tooling for your pill press machine depends on the type of machine you have.
It is easier to change the tooling in rotary pill press machines with detachable turrets.
Changing the tooling of a pill press machine requires tools such as allen keys, spanners, and pliers.
You also need to consider personal health and safety by having the appropriate gear and working on a plugged-off machine.
How Fast do Tooling for Pill Press Machines Wear Out and Break?
The tooling of a pill press machine executes the pill-making process through compression.
Besides, the compression process is a physically aggravating process to the punches and dies, contributing to their wear and tear.
The pill press machine’s frequency of operation will dictate how fast the tooling wears out and eventually breaks.
Additionally, the applied compression force also influences the rate of wear and breakage.
Can I get Custom Tooling for my Pill Press Machine?
Yes, you can.
You can get a manufacturer to make you a custom tooling to uniquely identify and present your pills.
When customizing your pill press machine’s tooling, you provide the manufacturer with a list of your desired specifications.
Do I need a License to own a Pill Press Machine?
The requirement to have a license to own a pill press machine is specific to countries.
Some countries require you to have a license, whereas others do not.
For instance, when purchasing a pill press machine in Australia or Canada, you will need an ownership license.
Contrarily, you don’t require a license to own a pill press machine in the European Union or the United Kingdom.
However, manufacturers in the USA need to submit formal documentation whenever they sell a pill press machine.
How do I keep my Pill Press Machine Clean?
Cleaning the pill press machine is necessary to prevent the accumulation of dust and dirt, contaminating the products.
Furthermore, cleaning can help you catch damage early, allowing you to rectify them, ensuring the machine
‘s smooth running.
You can expect a long and useful service life from your pill press machine with a good cleaning regime.
Some of the important steps you consider when undertaking a cleaning process include:
· Cleaning the External Surfaces
You can use a wet cloth to clean the pill press machine’s external surface to wipe off the dirt.
A vacuum cleaner can also be efficient in eliminating dust.
However, using compressed air can entrap dust and dirt in hard-to-reach areas such as crevices and between parts.
You find this occurrence can cause problems later, requiring expensive solutions.
· Inspecting the Machine
When cleaning, you need to carry out a visual inspection of the pill press machine to evaluate parts’ correctness.
You can easily identify instances of damage to parts allowing you to address them early before they get worse.
· Cleaning Preparation
You prepare to clean a press by removing detachable parts such as guards, frames, and plates.
Doing this allows you easier access to the interior and hard-to-reach parts of the pill press machine.
· Selecting Appropriate Equipment
When cleaning the pill press machine, you use brushes with soft bristles to prevent damaging sensitive machine parts.
For instance, a punch guide brush made for nylon allows you access to areas out of sight during the cleaning procedure.
· Selecting Appropriate Cleaners
The type of dirt influences the choice of cleaner since they contain different soils.
You will require different cleaners for oils and starch compounds such as those contained in the raw ingredients.
· Define a Cleaning Approach
A cleaning approach allows you to determine how much cleaning agent you need and even the appropriate water temperature.
You need to establish how long you’ll clean a particular part to achieve the desired cleanliness and cleaning method.
· Rinsing and Validation
A rinsing process allows you to eliminate any areas that still have detergent or cleaning agents on them.
Validation helps you identify areas omitted from the cleaning process allowing you to address them.
· Disinfecting and Drying
Disinfection eliminates any germs or harmful organisms present and typically follows the cleaning process.
Upon completion, you dry the parts using a dry cloth to prevent deterioration through rusting and loss of color.
Do Pill Press Machines come Fully Assembled?
Pill press machines consist of several parts, which you assemble on-site during the installation process.
When fully assembled, transporting the pill press machine is a daunting task full of risks that can cause expensive damage.
When transporting the pill press machine, packaging of parts separately prevents their damage during transportation.
You find these parts wrapped in bubble wrap or placed within fiber enclosures that absorb shocks during movement and handling.
How is the Durability of Pill Press Machine in Comparison to other Pharmaceutical Press Machines?
The pill press machine’s durability depends on factors such as the frequency of use and maintenance regime.
A well-maintained pill press machine can offer you a long service life as much as other pharmaceutical press machines.
How many Operators do I need for Pill Press Machine?
You have different pill press machines available at your disposal, including manual machines, semi-automatic machines, and fully automatic machines.
The number of operators you require for your machine depends on automation and the production output.
You will require more operators when you have a manual pill press compared to an automatic pill press.
Where you have a pill press with large output, your labor needs significantly increase to accommodate the production scale.
What is the Power Consumption of Pill Press Machines?
Pill press machines are available with different power consumptions that are dependent on the configuration and technical specifications.
You find many modern press machines are more efficient, consuming very low power compared to older models.
You are given power consumption ratings of pill press machines in horsepower per kilowatt.
You will find values such as 6.25 HP/4.7 KW and 9.5 HP/ 7 KW.
What is the Warranty for Pill Press Machines?
The warranty of pill press machines differs between manufacturers and depends on the model and type of pill press machine.
Some manufactures offer you between one and three-year warranties on your pill press machine.
Before purchasing a pill press machine, you can inquire from the sellers how long their warranty is.
A warranty offers you reprieve when your machine fails before the warranty period is over.
Multiple tooling system
Safety and contamination are important aspects when working with a pill press machine.
Safety ensures you do not injure yourself when operating the machine requiring the use of suitable PPE.
Additionally, when operating the pill press machine, you should prevent reaching your arm into the tooling area.
Furthermore, loose items such as hair and jewelry should be fastened and removed respectively.
When using the machine to make pills containing different excipients, you need to clean the machine every time before a changeover.
A cleaning procedure averts the possibility of cross-contamination that results in defective pills.
The cleaning process should involve removing the tooling system and the use of consumable grade oil for coating.
A die seat cleaner makes certain cleaning the die cavity is thorough before accommodating a new batch production.
At SaintyCo, we offer a range of pill press machines depending on specific needs of our clients.
Of course, this is alongside other pharmaceutical equipment.
For any questions or inquiry about pill press machine, contact SaintyCo now.