In this guide, you’re going to learn everything you need to know about the tablet press machine.
From parts, working principle, features, specification, cost to tooling configuration – you will learn everything you need to know about the tablet press machine.
Keep reading to learn more.
- What is a Tablet Press Machine?
- What are the Applications of the Tablet Press Machine?
- Why Should you Use Tablet Press Machine?
- How do you make a Tablet using Tablet Press Machine?
- What are some of the Tablet Shapes you can Make Using the Tablet Press Machine?
- Can you Coat Tablets after using Tablet Press Machine?
- What are the Parts of Tablet Press Machine?
- What equipment do you use alongside the Tablet Press Machine?
- What Parts of Tablet Press Machine Wear Out Faster?
- What are the Main Types of Tablet Press Machines?
- How does a Single Station Tablet Press Machine Work?
- Why should you use a Single Station Tablet Press Machine?
- What is the Limitation of Single Station Tablet Press Machine?
- How does the Rotary Tablet Press Machine Work?
- What are the Benefits Derived from using a Multi-Station Tablet Press?
- How is the Multi-Station Tablet Press Machine Limited?
- What is the difference between the Single Station and the Rotary Tablet Press Machine?
- What are Tablet Tooling Designs for a Tablet Press Machine?
- How do you Determine Material Suitable for Tablet Tooling Designs for Tablet Press Machines?
- How is the Tablet Press Machine’s Tooling System Classified?
- What are some of the Technical Specifications of a Tablet Press Machine?
- How much does a Tablet Press Machine Cost?
- What Quality Specifications should a Tablet Press Machine conform to?
- How do you Maintain Tablet Press Machine?
- How do you Troubleshoot a Tablet Press Machine?
- What is the Difference Between B Tooling and D Tooling in Tablet Press Machine?
- What is in a Factory Assessment Test for a Tablet Press Machine?
- What are User Requirement Specifications required for a Tablet Press Machine?
- How do you Test the Quality of Tablets Formed by the Tablet Press Machine?
- How do you set up a Multi-Tip Tooling Tablet Press machine?
- What is the difference between Main Compression and Pre-Compression?
- What is Turret in a Tablet Press Machine?
- Can you Customize Tablet Press Machine Tooling System?
- What is the difference between Tablet Specification Manual (TSM) and Euro Standard (EU)?
- How is Compression different from Compaction in a Tablet Press Machine?
- How does the Manual compare to the Automatic Tablet Press Machine?
- Why are Tablets made by Tablet Press Machines Popular?
- Why should you Coat the Tablet Press Machine Tooling?
- What is Tablet Hardness when using Tablet Press Machine?
- Does Dwell Time Affect Tablet Making when Using Tablet Press Machine?
What is a Tablet Press Machine?
A tablet press machine is a mechanical contraption you use to make tablets by compressing the powder.
A tablet is a dosage form in a solid unit filled with excipients that you use as a medicament.
You make tablets with similar weight and shape parameters using the tablet press machine.
The tablet press machine consists of a punch and die system that aid in the tablet making process.
The punch and die system can be motor driven or manually operated with either a single or multiple stations.
You can also refer to the tablet press machine as the tablet punching/tablet compression/tablet making or pill press machine.
What are the Applications of the Tablet Press Machine?
You use a tablet press machine to convert powder or granulated compounds into tablets of various shapes and sizes.
You then package these tablets and distribute them to their intended markets in determined quantities.
You find the tablet press machine applied across various industries, including:
Rotary tablet press
Rotary tablet press drawing
You use the tablet press machine in the food industry to make supplements for various food substances.
Common supplements include vitamin supplement and protein supplements used by multiple populations such as gym enthusiasts and health watchers.
You can also make a variety of confectionery and candy using the tablet press machine.
You can use tablet press machines with different die sizes and shapes to create a wider variety of candy.
Pharmaceutical and Herbal Industry
You use the tablet press machine to make drugs in tablet forms such as aspirin and paracetamols.
As the world continues to embrace natural remedies for illnesses, there is a need to package herbal medicine in conventional methods.
The tablet press machine is helpful when you package such herbal health products.
You find some chemicals such as cleaning and disinfectant products in tablet form.
You make these chemical products using the tablet press machine from their powder concentrates.
You find beauty products and enhancement in different forms such as ointments, lotions and even pills.
You use the tablet press machine to make beauty tablets used to instigate external changes such as complexion.
Why Should you Use Tablet Press Machine?
The tablet press machine allows you to make tablets of various shapes and sizes for multiple purposes.
You also find the following advantages when using the tablet press machine:
i. Ease of Operation
The tablet press machine is simple to operate whether you use a manual or automated type.
The operation of the tablet machine involves very few complex commands or manoeuvres.
ii. Increased Efficiency and Accuracy
When making tablets, you need to be efficient to ensure minimal wastage of powder.
It would help if you had your tablets of similar weight and size, primarily when intended for dosage.
When you use a tablet press machine, you achieve consistency in tablet making in the required weight and size.
Consequently, you have similar tablets as per the production requirements.
iii. Time Savings
Using a tablet press machine that is automatic allows you to make a tablet in minimal time.
Furthermore, when you use a rotary press tablet machine, you can create multiple tablets at a single interval.
iv. Increased Output
The reduced period for producing one tablet results in an increase in your production levels.
You achieve a higher tablet count when using the tablet press machine and even more using the rotary press machine.
How do you make a Tablet using Tablet Press Machine?
Tablet making using the tablet press machine is dependent on a dual punch set and a die.
A punch is reinforced tooling furnished from hardened steel while the die supports the material you work on.
Using the following steps allows you to make a tablet using a tablet press machine:
i. You lower the punch on the bottom side into the die, making a cavity where you enter the powder material.
You regulate the amount of powder allowed into the cavity by adjusting the punch’s depth.
ii. You remove excess material from the die top before lowering the bottom punch and inserting a cover to prevent material spillage.
iii. Thereafter, you lower the top side punch, which interacts with the powder material in the cavity, simultaneously removing the cover.
A compressional force provided by the compression rolls under high-pressure compact the powder material forming a solid tablet.
iv. Upon completing the compression procedure, you release the tablet by raising the bottom side punch.
What are some of the Tablet Shapes you can Make Using the Tablet Press Machine?
You use compressional force to make the tablet using the punch and die set in a tablet press machine.
The die determines the shape of the tablet since it holds the powdered material for punching.
You can design the die to allow you to make tablets in many different shapes, some of which include:
Can you Coat Tablets after using Tablet Press Machine?
You employ a different machine integrated with the tablet press machine called the tablet coating machine.
You can use it during the coating process.
Tablet coating machine
The coating is a procedure where you apply an external dry layer to a tablet to provide certain desired benefits.
The coating process typically involves the application on the tablet of a polymeric or sugar coat.
While coating increases your cost of production, you achieve the following useful features for your tablet:
- You improve on the physical strength of the drug when you use a coating.
- You conceal unpleasant tablet features such as smell, taste and colour.
- Some drugs are susceptible to the acidic stomach environment, and therefore using a coating protects them.
- When you use a coating on a tablet, you can regulate the drug release from the tablet.
- The coating allows you to provide a protective layer to the tablet from physical or chemical agents.
- You can include another drug strain in your coating to address incompatibility issues.
What are the Parts of Tablet Press Machine?
Parts of single punch tablet press machine
The tablet press machine consists of several parts that allow it to function in its tablet making role.
The parts have specific roles that ensure your use of the tablet press machine is smooth and has no setbacks.
You begin the process of compressing a tablet at the tablet press machine hopper.
Also, you find hoppers with different designs, sizes and shapes to go along with your tablet press machine’s capacity.
Besides, you use the hopper to feed the powder material you want to convert into tablets.
The hopper is usually stainless steel and built to allow the powder’s impeccable flow into the cavity for compression.
You can manually feed your hopper or have it automatically fed with a Programmable Logic Controller (PLC).
The level of automation is dependent on the type of tablet press machine you use.
You can use unique angles of flow with your hopper to facilitate the optimal powder flow or include a vibratory feature.
With these strategies, you enhance the flow of material, lowering the chance of material separation and starvation of the feeder.
You need to ensure the feeder receives the appropriate amount of material and release it to the die cavity for compression.
The feeder is composed of two main parts: housing and pebbles.
The feeder housing is where the powder released from the hopper gains entry into the punch and die system.
The housing is constructed with stainless steel to prevent product contamination.
You need this process to be impeccable in its execution to ensure you produce appropriately sized tablets.
Additionally, the powder material shouldn’t adhere to the housing’s surface to eliminate potential variations in the feeding process.
The feed pebbles ensure the powder material fed into the die cavity is steady and precise, especially for high-speed machines.
Otherwise, you can have incompletely filled dies, affecting the tablet quality by having different thicknesses due to dissimilar compaction.
Tablet press punch and die system
You have a pair of tablet press punches made from hardened steel or tungsten carbide with different shapes and sizes.
The design of your tablet press machine punches directly affect the quality of the tablet.
You need precise tablet press punches made with the utmost accuracy levels to ensure their resulting product is superior.
You find the operation of punches subjects them to continuous high pressure and harsh environment.
Therefore, when making tablet press punches, you employ resilient material with coatings to minimize wear.
You have two punches, one located on the top side and the other on the die cavity’s bottom side.
The top punch is positioned on the rotary system’s top half, while the bottom punch is lower.
The top punch moves in an up and down motion into the die cavity during the compression process.
You hold it in the die cavity’s desired position during the compression process for the bottom punch.
The compression process initiated by the tablet press punches in the die cavity produces the tablets in the desired shape.
iv. Die System
The die system works in unison with the punches as the die cavity holds the material the punches act.
You need to machine the die and punch together to ensure they mate for an efficient compression procedure.
The die allows you to produce tablets in the required size and thickness by compressing the powder or granular material.
You find the following features essential for your die system in a tablet press machine:
- The die system should be such that the powder material does not adhere to its surface.
- Your die system should prevent fragmenting of the tablets.
- The die system should not be susceptible to the effects of corrosion.
- You need to position the die and punch such they mates correctly during the compression process.
- The tapering angle allows you to reduce the heat produced by friction during compression and the force of releasing a tablet.
- You also ensure the die parameters of height and cavity diameter areas required to make tablets in the desired sizes.
Remember, they form an integral part of tablet press tooling system.
Tablet press turret
Turrets are a vital feature of the tablet press machine with a rotating component that contains the die.
You observe the dimension of the turret and rotational tolerance to be precisely set during their construction.
The turret has holes that ensure the full alignment of the die and punch that optimizes making tablets.
You can improve the turrets’ efficiency levels and consistency by providing room for adjustment to accommodate the dynamic compression process.
You find many manufactures providing turrets as segmented features with separate elements such as punches.
Such turrets are useful in enhancing the production levels of a tablet press machine and operational efficiency.
You can fashion multiple compression stations with the segmented turret while also improving part swopping.
Consequently, you record increased tablet outputs with this design for a complete rotation.
Furthermore, when using a tablet press machine with high production capacity, you can use punches with multiple tips.
You find this possible through efficient tolling system design you can customize while conforming to the TSM and EU tooling standards.
vi. Cam Tracks
The cam tracks regulate the punches’ movement during the compression process providing you with a smooth tablet making operation.
The cam tracks direct the vertical movement of the punches as the turret makes a rotation.
Controlling punch movement ensures just the right amount of powder is allowed into the cavity.
You also find this critical in determining the force applied during compression and also removal of complete tablets.
You observe an inflow of powder into the die cavity when the top side cam track pulls out the top punch.
The cam track below initiates an upward motion for the bottom punch into the cavity at the same time.
Tablet press process flow
When the die cavity is full of powder or granular material, the cam tracks adjust the amount by moving the punches.
Thereafter, the cam tracks direct the top and bottom punch into positions that enable maximum force’s exertion.
When the applied force results in the desired tablet form, the cam track releases the top punch.
Simultaneously, the bottom cam track pushes the bottom side punch upwards, releasing the cavity tablet.
Consequently, you find the cam tracks’ role essential in the tablet making process using a tablet press punch.
Thus, the cam tracks are central in achieving tablets of the required form and feature.
vii. Filling Station and Weight Control
The cam tracks determine the amount of material flow into the die cavity by adjusting the top and bottom punches.
However, you find servo motors useful in guiding the cam tracks’ movement, thus providing precise measures.
You can easily integrate servo motors in your tablet press machine to work alongside other computerized functions.
You determine the weight of the powdered material by regulating the depth of the fill in the bore.
The lower cam track guides the bottom punch movement to the desired level to which the filling process adheres.
Consequently, achieve a certain depth when you release powder material into the cavity.
When you have excess material entry into the cavity, you can remove the excess by moving the bottom punch upwards.
Usually, the tablet press machine is such that the excess material fills up the subsequent die cavity.
viii. Compression Rollers
The compression rollers serve to make sure the compression of the powder results in the required form and dimensions.
An essential role of the compression rollers is to eliminate air trapped amongst the material particles.
The compression rollers eliminate air within the powder structure by subjecting it to an elevated compression exertion using a roller system.
Subsequently, the powder is rid of air before the actual compression process commences.
You have two sets of compression rollers in your tablet press machine: the pre-compression rollers and the main compression rollers.
You find the pre-compression rollers are at the fore of the rotary press.
Pre compression and compression in tablet press
The pre-compression rollers eliminate air within the powder structure and cavity by applying a minimal force on the punches.
You note that air in the bore and material hamper the integrity of the tablet formation process.
You employ the main compression rollers for tablet formation of defined specifications under a set force exertion.
The force used during the main compression exceeds that of pre-compression.
When carrying out the main compression, ensure you have your rollers steady devoid of movements such as vibration.
Indeterminate movement negatively impacts the tablet formation process resulting in tablets with varying thickness and dimension.
ix. Ejection Cam
The ejection cam is in succession to the main compression rollers.
The ejection cam allows you to retrieve the finished tablet after the compression process from the die cavity.
The ejection cam works by directing the lower punch upwards progressively while the upper cams withdraw the top punch.
You note that this movement causes the compressed tablet to eject from the bore and rest at the die top.
x. Take-off Blade and Discharge Chute
You find the take-off blades directly above the housing for the feeder.
These blades push the newly formed tablets into the discharge chute from where they head to the collection container.
The discharge chute is simply a passage that provides a means to collect the tablets for packaging in the container bin.
xi. Control Panel
The control panel of a tablet press machine is touchscreen-enabled, allowing you to direct the processes involved in tablet making.
Besides, the touch screen panel is an HMI you attach to the tablet press machine’s central unit or operate separately.
You have many options in the market for the touch screen control panel Human Machine Interface (HMI).
The control panel enhances operation efficiency allowing you to control and direct several functions by the fingertips.
xii. Sealing System
With the sealing system, your tablet press machine acquires a highly developed capability for handling dust.
Tablets such as pharmaceutical and nutraceutical are formed for oral ingestion into bodies and thus require clean environments during their manufacture.
The sealing system provides increased isolation to the tablet press machine, ensuring the machine is always clean.
Furthermore, with the sealing system, you are bound to experience reduced contamination levels for your machine during tablet formation.
xiii. Motors, Gears Systems and Belts
You find parts mentioned, such as the rollers, turrets, punches, and dies, are mobile, requiring a prime system to provide motion.
You can employ a servo motor for your motion needs or an induction motor based on the desired movement.
You use a servo motor when creating motion for your filing system due to the simplicity of attaining adequate precision controls.
Alternatively, you use synchronous motors for the pre-compression and compression rollers due to their impeccable control and speed.
Gears and belts systems are useful when transferring motion across sections in a tablet press machine.
You note that these machines support load compensation in case of variations.
Consequently, you can start a tablet press machine with a motor on full load and even bearing no load.
Nonetheless, you attain motion by using a diverse system mix encompassing electrical, mechanical and hydraulic systems.
xiv. Lubrication Systems
A tablet press machine has several moving parts requiring lubrication to prevent wear and tear caused by sustained friction.
Due to these machines’ size, it is efficient to have a centralized system for lubrication.
In this case, the system entails channels from a central position to movable parts where you need lubrication.
You then have the lubricant discharged at the required point automatically via programmed control or by manual intervention when needed.
xv. Hydraulic Unit
You require pressure in the tablet press machine to guide the compression process of tablet formation.
The pressure levels needed for the hydraulic pump have to be unswerving to support pre-compression and main compression.
A steady hydraulic system ensures the tablet formation process is precise and efficient.
Excess pressure can damage the press tooling unit; thus, you use a protective component in mitigation.
The protective component acts as a breaker halting the machine when an overload is detected.
Subsequently, you protect the tablet press machine from imminent damage.
What equipment do you use alongside the Tablet Press Machine?
You achieve tablet making using the tablet press, which compresses powder material of the desired formulation via a punch and dies system.
However, while the compression process occurs in the tooling station, you must prepare the powder beforehand.
Furthermore, after compression, you can coat the powder and package them in various measures for transportation.
Therefore, you can classify the equipment you use alongside tablet press machines as pre and post-compression process.
- Some of the equipment you use in preparing the powder material before the compression process include:
1. Equipment for Material Size Reduction
You use these equipment to reduce the size of substances used to prepare material to make tablets.
These equipment include:
A hammer mill is a contraption composed of multiple hammers you use to crush lumps of material into smaller pieces.
The hammer mill operates on an impact mechanism where material fragmentation occurs by the hammering process and collision.
The vibration mill consists of a spring supported tube containing small balls of stainless steel or ceramic.
You find these balls occupy about two-thirds of the tube volume, creating a continuous impact process to crush material.
A roller mill composes a single or multiple wheel system you rotate to crush materials through stress application.
You can use a roller mill for various solid materials along those contained in suspensions in addition to pastes.
The pin mill configuration of a dual plate system is horizontal, with pin-like projections to initiate impact.
You use the pin mill to fragment material for tablet formulation without destroying their chemical institution.
Fluidized Energy Mill
A fluidized energy mill employs a gas or fluid jet under high pressure located at the base to excite material particles.
The particles move at elevated speeds breaking apart via impact and attrition.
The end-runner mill is essentially a motorized pestle and mortar system that simulates the grinding of material via impact and shear force.
An edge-runner mill consists of heavy rollers rotated about a cradle of large stones that crushes material in between.
You observe the weight of the rollers and stones alongside the friction that induces the substance reduction.
A cutter mill employs multiple knives, with some circular motion and others fixed that break apart the material.
The cutter mill works well when reducing roots and tree barks to extract excipients.
A ball mill contains numerous balls of different sizes within its cylindrical form used to break down material by rotation.
The balls’ movement interacts with the material, grinding and crushing it apart via attrition and impact.
2. Equipment For Weighing Material
You find the weighing equipment useful in determining the weight measures for the materials, including:
Bulk Weighing Balance
You use the bulk weighing balance to measure the weight of material for tablet formulation in kilograms.
Electronic Weighing Balance
The electronic weighing balance allows you to measure small weights in grams and milligrams.
3. Equipment For Mixing Material
You have various equipment for use in the mixing process of tablet material formulation such as:
You use compressed air to drive the pneumatic mixer initiating a mixing process of different substances to form a homogenous compound.
The diffusion mixer consists of a container that you rotate to create a movement that initiates the mixing of materials.
The mixing mechanism you use is diffusion with various types, including the cubic mixer, V-blender, drum blender and double cone blender.
A convective mixer is a stationary container whose mixing process employs a rotating device within such as a blade or screw.
The mixing approach you employ here is convective with elements of shear and diffusion.
You have various convective mixers like orbiting screw mixers, horizontal double arm and high-intensity blenders, planetary blenders, and vertical high-intensity mixer.
A granulator helps you convert your mixed formulation for the compression process by a roller press into small free-flowing particles. Some common granulators include:
Rotating Shape Granulators
A rotating shape granulator moves moderately in a rotation along a horizontal axis to initiate the material’s granulation process.
Mechanical Agitator Granulators
This granulator type employs a low shear mechanism to combine the raw substances with a binder agent into granules.
A motor drives the high-shear granulator, consisting of a mixing bowl, chopper system, impeller, and discharge basin for granulation.
You can carry out three different processes with this granulator, including mixing and drying.
It is a piece of popular equipment that employs a bubbling cradle approach.
A dry granulator enables dry granulation where you carry out granule formation minus the liquid solution’s involvement.
4. Equipment For Drying
Some common drying equipment you can use for your tablet making process include:
A spray dryer works continuously, accepting material that it atomizes, producing precipitations you dry via evaporation using hot air.
A rotary dryer uses a tumbling approach to eliminate moisture from materials using hot gases while in a rotation.
Fluidized Bed Dryer
The fluidized bed dryer uses fluidization where inlets at the base allow passage of hot air under high pressure.
The pressure lifts the wet particles in a continuous stream vaporizing the moisture, which is gas-eliminated.
Some of the equipment you use after the tablet compression process includes:
5. Equipment For Quality Control
Quality control ensures your tablets meet your determined standards while complying with the regulatory standards.
Some common equipment you employ for quality control include:
Disintegration equipment allows you to test the disintegration process of a tablet in a solution.
USP Dissolution Tester
With this equipment, you assess a tablet’s dissolution in a solution under a highly regulated environment.
Tablet Hardness Tester
You use a tablet hardness tester to establish the physical toughness of a tablet under stress conditions.
Tablet Thickness Tester
A tablet thickness tester allows you to determine your tablet’s thickness and whether it falls within the expected range.
Tablet Friability Testers
Friability describes the tendency of a tablet to crumble under the application of pressure.
The friability tester simulates such pressure applications ensuring your tablet doesn’t succumb easily to duress.
Metal detectors allow you to identify and remove tablets with any metallic traces in the powder.
Bits of metal pieces from the tooling system can occur in the tablets due to breaking or grinding.
Tablets, especially those you use for pharmaceutical purposes, need to have similar weights for dosage purposes.
A weight checker allows you to establish each tablet’s weight, eliminating those outside the required range.
6. Machines For Coating And Polishing
Tablet coating machines allow you to apply an external dry layer on the tablets to achieve the desired objective.
You can enhance the taste, colours and texture of tablets using coating and polishing machines.
Standard Coating Pan
The standard coating pan is one of the most popular coating equipment consisting of a wide plate rotated by a motor.
You can tilt the plate and have the tablets tumble in the coating as the pan rotates.
With a perforated pan, the pan features holes made across the base to boost airflow.
A perforated pan enhances the coating speed.
Spray Coating System
In this system, you apply a coating to your tablet via a spray method on a fluidized bed.
You apply the coating via an air suspension approach that ensures the coating is even on your tablet.
7. Packaging Machines
Tablet making machines can produce very many tablets in a minute which is challenging to package by hand.
Tablet packaging machines contain the tablets in cases or bags in their appropriate measure or count.
Blister Packaging Machines
The blister packaging machine uses heat and vacuum condition to create a blister for containing the tablet.
You thereafter seal the tablet filled blister with backing such as paper.
Strip Packing Machine
In strip packing, you enclose the tablet between a pair of foil sealable by heat application.
You can seal multiple tablets using a single foil pairing.
Aluminium Foil Packaging Machine
Aluminium packaging allows you to contain tablets in light and flexible material.
You also protect the tablet(s) from elements such as excessive light and radiation, water molecules and oxygen.
Other equipments used alongside the tablet press machine are:
You use a deduster to eliminate dust caused by the tablet making process from the machine.
The dust usually consists of particles of the tablet making material.
Tablet Counting Machine
A tablet counting machine allows you to count tablets for packaging or dosage purposes.
What Parts of Tablet Press Machine Wear Out Faster?
When a part wears, it ceases to exhibit the former efficiency in operation and can also bear physical marks of deterioration.
The movable part is most likely to wear out ahead of other parts in the tablet press machine.
Also, the compression rollers, the die and punch system alongside the turrets, and take-off blades will experience wear much earlier.
The punch and die system will exhibit wear sooner due to their continuous movement during tablet formation from among these features.
What are the Main Types of Tablet Press Machines?
The tablet press machine is useful in the manufacture of tablets across various industries in different capacities.
You have two major tablet press machine types as follows:
Single Station Tablet Press Machine
Single punch tablet press
The single station tablet machine is known as so due to having only a single tooling dock.
The single tooling station comprises a die with a punch pairing located at the top and bottom.
You can also refer to the single station tablet press machine as the eccentric press.
The single station press is the simplest form and is available in different designs and arrangements proportional to your needs.
When using the single station press, the tablet formation process depends entirely on the top punch force.
Multi-station Tablet Press/Rotary Tablet Press
You refer to this tablet press machine type as the multi-station press because it supports more than one tooling station.
You typically have the tooling stations moving in a rotation, thus lending the other name of rotary tablet press machine.
With a multi-station press, you achieve a higher output compared to a single punch press.
You can tell the production of a rotary tablet press machine by counting the tooling units it supports.
The rotary machine supports several top and bottom punch pairings that allow you to make several tablets in a single rotation.
How does a Single Station Tablet Press Machine Work?
You know, on a single station tablet press machine, you have a top and bottom punch pair and a die.
You make a single tablet in the tooling system by a punch-stroke that compresses the bore’s powder material.
The working of a single station tablet press machine takes the following process:
- The powder material consisting of the required tablet’s required formulation enters the machine via the hopper.
- After that, this material enters the feeder, allowing the appropriate amount of material into the die cavity.
- The bottom punch’s precise movement determines the required amount of powder compressed into a tablet form.
- The top punch exerts the required force to compress the powder into a tablet while you maintain the bottom punch position.
- The tablet making process ends with the tablet’s ejection from the die cavity by the ejection cam’s action.
Why should you use a Single Station Tablet Press Machine?
The output of a single station tablet press machine is lower than that of a multi-station machine.
However, you derive t hollowing benefits from using the single station press:
- The cost of acquiring a single station press is considerably lower than the multi-station press.
- Using the single station press is less demanding in skill due to its straightforward application.
- Loading the material in the die cavity if a single station press is less complicated.
- The single tooling kit ensures the tablet making process is consistent every time.
- The single tooling kit makes this tablet press machine small allowing you to use it in limited space.
- When carrying out small scale operations, using the single station tablet press is convenient.
What is the Limitation of Single Station Tablet Press Machine?
You find the single station tablet press machine limited in a few aspects as follows:
- Most single station press machines have low output levels making them unsuitable for large productions.
- When using a single station press, the process is slow, requiring more extended periods to achieve a specific output level.
How does the Rotary Tablet Press Machine Work?
You find the rotary tablet press machine popularly used in industries with large scale production like pharma.
You have different rotary tablet press machine models, including the single rotary, high-speed rotary and single-sided rotary press machines.
The basic working tenet of these models, however, is similar and includes the following procedures:
· Feeding the Machine Material
You feed the formulated powder material for your tablet to your rotary press machine via the hopper.
You can feed the hopper with material manually or through an automated process controlled by a programme.
The powder enters the feeder from where an appropriate measure enters the die cavity.
Also, the feeder has a housing unit and pebbles, which receives the powdered material and guides entry into the tooling system.
· Die Filling Process
Before you have a tablet compressed, you fill the die cavity with the appropriate measure of powder.
Having excess material is highly discouraged as it brings about inconsistency in the tablet making process resulting in different tablet thicknesses.
The cam tracks regulate the powder’s weight by adjusting the top and bottom punches to predetermined levels.
As it is a multi-station press, you transfer the excess powder to the succeeding die cavity to prevent wastage.
· Tablet Making Process
The rotary tablet press has multiple tooling kits supported by turrets that can move in a rotation.
Also, the number of tooling kits on the turret varies with them determining the production output.
Furthermore, the turret consists of three parts: the upper and lower turret, and the die table.
The upper turret holds the top side punches, whereas the lower turret holds the bottom side punches.
Besides, the die table supports multiple die cavities filled with the powder material before the compression process.
Again, the respective paring of top and bottom punch controlled by cam tracks exert the necessary pressure for compression.
Compression occurs two-fold: pre-compression, which eliminates air in the powder and main compression, making the tablet in the desired form.
The compression process is executed for all the die cavities by the punch pairing as the turret rotates.
After the compression process, the tablet needs to remove more powder in the cavity for another tablet’s compression.
The upper section’s cam tracks withdraw the top-side punches while the ejection cam below pushes the bottom-side punches upward.
Here the cam controlled motion of the punches ejects the compressed tablets from the die cavity.
Take-off blades appropriately positioned above the die cavity thereafter push the tablets towards the discharge chute.
The discharge chute channels the tablets into a container bin from where you collect the production haul.
Upon completing the production process, you package the tablets according to your requirements.
What are the Benefits Derived from using a Multi-Station Tablet Press?
The multi-station tablet press machine allows you to enhance your tablet output, making the process significantly.
Using its multiple tooling kits, you can achieve an output over hundreds of thousands of tablets every hour from one machine.
Consequently, you can use the multi-station tablet press machine in industries requiring voluminous tablet production, such as pharmaceuticals.
You have a wide array of multi-station press machines to choose from with different designs offering you robustness, efficiency and reliability.
Other benefits you extract from using the rotary press machine include:
- Most multi-station tablet press machines are automated, making you incur less cost in producing tablets with reduced labour needs.
- While operating this machine is not complicated, you achieve better weight measures due to its high accuracy level.
- The multi-station pre-machine is easily compatible with other computerized function allowing for consistency in production.
- As you can produce multiple tablets in a single rotation, you achieve faster production times for large batches.
- The multi-station tablet press machine is highly efficient as you experience minimal wastage of material during the tablet making process.
- The reduced human presence required to operate the multi-station press reduces the likelihood of errors that hampers the process.
- Increased automation in the machine allows you to regulate and determine the tablets’ weight and hardness independently.
- The machine manages the operations in the die cavity, automatically minimizing losses and inaccuracies in the process.
How is the Multi-Station Tablet Press Machine Limited?
As expected, you consider certain aspects of the multi-station tablet press machine to be limited in form or function.
Some of the notable limitations associated with the multi-station press are:
- Obtaining a multi-station press machine and installing it is an expensive venture that costs you an arm and a leg.
- You need large space requirements for your multi-station tablet press due to its size. Consequently, you incur more in rent costs when you acquire such a machine.
- The multi-station tablet has highly automated functions allowing you to cut on labour cost. However, the machine’s complexity requires you to acquire highly skilled labour or undertake a training process.
- There are environmental concerns when working with a multi-station tablet press machine due to its emissions and releases.
Multi-station tablet press
What is the difference between the Single Station and the Rotary Tablet Press Machine?
You find both the single station tablet press and the rotary tablet press machines useful in tablet production.
You can achieve different output levels using both these machines while they both employ the same working approach.
Some of the notable differences you encounter with these machines are:
i. Number of Stations
The single station press and rotary tablet press differ in the number of tooling kits they possess.
You have only one tooling station in the single station press, whereas the rotary tablet press supports multiple stations.
The multi-station tablet press machine employs a feature called a turret that rotates and supports multiple tooling stations.
ii. Speed of Operation
You achieve a faster production time for a defined batch when using the multi-station press than the single station press.
You make a single tablet for a complete compression process with a single station press, taking a long time to meet production.
When using a multi-station press, you achieve multiple tablets for a single rotation of the compression process.
You get numerous tablets from the multiple tooling stations available on the turret.
iii. Output Level
Due to the single tooling kit in a single station press, you achieve a lower tablet output for every production minute.
On the other hand, you produce several tablets in a minute using the multi-station press.
The multi-station press supports several tooling stations allowing you to make multiple tablets in a single rotation.
You can complete several stations in a minute, besting the output of a single station press machine.
iv. Method of Compression
When using the single station press, you observe the compression process involves only the top side punch.
Keep the bottom punch steady as the top punch employs a hammering technique to exert force on the powder.
With the multi-station punch, both the top punches and the turret’s bottom punches work to compress tablets.
You find the cam tracks on either side position the punches to initiate the tablet formation compression process.
What are Tablet Tooling Designs for a Tablet Press Machine?
The tablet compression process’s efficiency depends on the tablet tooling design of the tablet press machine.
You find the tablet tooling system determines several characteristics of the tablet formed, such as the size and shape.
You determine all the physical aspects of a tablet by the tooling design you employ for your tablet press machine.
You consider several features like the headset shape, the back angle and radius and the punch shank during tooling design.
Several factors affect the eventual tablet tooling design you undertake and the nature of components used.
Some of the factors include:
Tablet press tooling system
- Material you use for the tooling kit.
- Design path you undertake for the tooling kit.
- Industry standards specified for your tooling set.
- Specifications provided for the tablets you intend to make with your tooling set.
- Type of tablet press machine you are using.
When selecting a tablet tooling design for your tablet press machine, you have various options from which you can pick.
Major classifications of the tablet tooling design available for you are:
Standard Tooling Kit Design
The standard tooling system design is the least costly to undertake, thanks to its simplified set-up.
You can use the standard tooling kit design on tablet press machines you intend to use for small scale productions.
You can create tablets of different shapes with the standard tooling kit design such as rectangular, circular and concave.
Furthermore, you can fashion your standard tooling kit design to include extra elements, including emblems, symbols and letters on the tablet.
Custom Tooling Kit Design
A manufacturer makes a custom tooling kit design according to your requirements and specifications.
When you employ a custom tooling kit for your tablet making process, you achieve uniqueness in your production.
There are several aspects you can customize for your tablet when you employ the custom tooling kit design.
You can customize the shape of your tablet and the dimensions preventing other manufacturers from imitating your product.
Therefore, you find a custom tooling system design that ensures your products are different in the market.
When you uniquely present your products, you maintain a market presence that allows you to compete favourably.
Multiple Tooling Kit Design
Multiple tooling system designs allow you to make tablets in various shapes and sizes.
You find this tooling kit design is essential when you have a broad product portfolio.
When you use multiple tooling system designs, you can support a high production output of different tablet formations.
You find this tooling kit design useful when working on numerous and varied short orders.
How do you Determine Material Suitable for Tablet Tooling Designs for Tablet Press Machines?
The tooling system design for your tablet making process is vital as it dictates your tablet’s physical appearance.
You find the tablet making process is rigorous, with many friction-inducing movements requiring the tooling kit to be formidable.
Consequently, the material you use for your tooling kit has to be durable to sustain several tablet making operations without fail.
You find hardened steel and tungsten carbide commonly employed for the tooling kit in many tablet press machines.
The following factors allow you to evaluate the suitability of material during the design of your tooling kit:
- The material you employ has to have superior physical qualities to tolerate the tablet making process’s rigours.
When you use material with exceptional physical properties, it responds well to wear and tear conditions.
- You need to ensure, your material is highly resistant to induced deterioration such as corrosion.
Corrosion perpetuates contamination which affects the quality of your tablet composition with the potential to pose serious health risks.
- The material you use for the tooling kit needs to conform to the industrial standards provided guiding the design process. For instance, ensure your material complies with the industry’s current Good Manufacturing Practices (cGMP).
- When selecting a material for your tooling kit, it should support the applied compressional forces without failing.
The ability to withstand these forces speaks to its longevity, robustness and dependability.
- Factors internal to the tooling kit also influence your choice of material, such as the turret’s rotational speed.
Additionally, the depth of the cup of your die cavity will guide you on what material to implement for your tooling system.
How is the Tablet Press Machine’s Tooling System Classified?
The classification of the tooling system is dependent on the diameters of the punch barrel and the die.
You use the external diameter for the die rather than the internal diameter in the classification.
Classification of the tooling system helps you discover your tablet press machine’s capacity for production.
You find four common categories for the tooling system denoted: B, D, BB and DB.
The B type tooling system has a punch barrel diameter of 19 mm and an outer die diameter of 30.16 mm.
For the D type, the respective punch barrel and die diameters are 25.4 mm and 38.10 mm.
The BB and DB have a punch barrel diameter of 19.0 mm and 25.4 mm, respectively. Their outer die diameters are 24.0 mm and 30.16 mm, respectively.
What are some of the Technical Specifications of a Tablet Press Machine?
You describe a tablet press machine’s technical specifications as those related to the machine’s functional capability.
Technical specifications allow you to evaluate the suitability of a particular tablet press machine to your needs.
Some specifications you consider for your tablet press equipment include:
Tablet press machine
i. Model of the Machine
Usually, manufacturers offer you, different models, for a particular tablet press machine, with the difference lying in the technical aspects.
You find more recent models with advanced technical specifications and capabilities than previous models.
Some aspects of newer models that improve older models include current and power ratings and even operational speeds.
When purchasing a tablet press machine, you need to consider newer models as improved versions of older models.
Furthermore, when you purchase a newer model, you are likely to get up to date support for your tablet press machine.
Obtaining things such as spares for older models can be challenging as you may find them outdated.
ii. Turret Specifications
You consider turret specifications when purchasing a multi-station or rotary tablet press machine.
Turret specifications are vital since the turret unit is the central processing unit for a rotary tablet press machine.
The turret supports the tooling stations essential for the formation of tablets through the compression process.
Essential features you consider for the turret include the quality of material, the speed of rotation and the compression forces applied.
The quality of material allows you to determine the capability of the material in your use.
Alternatively, the compression forces supported by your turret will inform you whether your intended use meets the threshold.
iii. Control System
Many tablet press machines are automated, with the automation levels differing from one machine to another.
You find automation in tablet press machines guided by a control system allowing you to tinker with programming.
According to the specifications, the control system is a Human-machine Interface (HMI) with varying control levels.
While you can modify programing for your tablet press machine in some, others only allow you remote control.
iv. Construction and Build
You find tablet press machines with different constructions and build to support different production levels.
Your selection of a tablet press machine will depend on what output you intend to attain in your usage.
You have two construction options to choose from, that is, single station construction and multi-station construction.
You achieve higher production with you go with the latter compared to the former.
Important technical aspects you consider when evaluating the build of your machine include the weight and dimensions.
Dimensions are useful in determining the machine well suited to your space since you don’t want to buy something you cannot house.
How much does a Tablet Press Machine Cost?
You have a wide variety of tablet machines from which you can choose to meet your tablet production needs.
However, you find these different tablet press machines attract different prices in the market.
Additionally, you have two major classifications of the tablet press machine; the single station and the multi-station press machines.
These machines differ in their construction, influencing their output levels to observe more productivity with the multi-station.
Considering these factors, you find the multi-station tablet press machines are comparatively pricier than single station press machines.
Furthermore, you will observe price differences where you have improvements in aspects such as speed and efficiency.
However, you can find simple single station tablet press machines going from about 3000 USD.
However, advanced multi-station tablet press machines can fetch higher prices in the hundreds of thousands of dollars.
What Quality Specifications should a Tablet Press Machine conform to?
Quality specifications of the tablet press machine ensure they adhere to set industry standards regarding value and use.
You find the quality specifications of tablet press machines protect you from purchasing inferior and harmful machines.
Quality specifications by relevant institutions guide certain aspects of the development or use of the tablet press machine.
These institutions lend their names to the specifications, including:
Quality Standards as Stipulated by the FDA
The Food and Drug Administration (FDA) evaluates the compliance of food and drug substances and equipment used to set standards.
For instance, pharmaceutical and nutraceutical companies employ the tablet press machine to make medicinal drugs and supplements for human consumption.
Consequently, you find these machines and processes employed have to be qualified as not posing any health hazards.
For instance, the materials used in the production equipment should be non-carcinogenic.
· ISO Standards
The ISO is the International Standard Organization that confers certifications to manufacturers across various industries, including those making tablet press machines.
You find guidelines to attain the quality levels required for ISO certification when making tablet press machines.
· Consumer Electronics Standards
You find tablet press machines are powered by electricity and have to conform to electrical protocols provided guiding such machines.
For instance, insulation of the tablet press machine’s electrical cabling protects you from shocks.
· cGMP Qualification
Current Good Manufacturing Practices certification ensures the tablet press machine you purchase is safe for use in harmless manufacture.
Furthermore, cGMP recommendations ensure your tablet press machine’s design is ergonomic to suit the population needs.
Are Validation Documents required when purchasing a Tablet Press Machine?
Every time you purchase industrial machinery such as a tablet press machine, you need validation documents.
Validation documents are useful endorsement articles for your tablet press machine and its suitability for operation.
Common validation documents offered with a tablet press machine include:
Factory Assessment Test (FAT)
You receive the Factory Assessment Test documents form the manufacturer upon confirmation of the tablet press machine’s worthiness.
Manufacturers perform this test on finished press machines ensuring they conform to the design specifications.
Installation Qualification (IQ)
When you successfully install the tablet press machine at your site, you get the installation qualification documents.
The installation encompasses the location of all the connected parts and their start and stop protocols.
You also find the emergency buttons and safety features such as guard rails indicated on the installation qualification documents.
These documents also describe the safety protocols to follow during emergencies such as fires.
Operational Qualification (OQ)
A successful installation process doesn’t usually mean a successful operation procedure and hence the separate documentation.
Once the machine completes a test run, you get OQ documents, successfully responding to program controls as expected.
How do you Maintain Tablet Press Machine?
Maintaining a tablet press machine is vital if you intend to extract a long and useful service life from it.
Furthermore, you can nub defects and failings early on before they can cause lasting damage to your machine.
Proper maintenance entails the following actions:
i. Cleaning the Machine Regularly
Cleaning involves dusting off, wiping and drying parts of the tablet press machine to remove accumulated dust and powder residue.
You can use certain detergents and solvent cleaners that cause no reaction with the tablet press machine materials.
You find cleaning vital as it prevents dirt and can contaminate the powder material used in tablet making.
Contamination is especially dreadful when the tablets are for pharmaceutical or nutraceutical usage.
ii. Routine Inspection of the Machine
Regular inspection of your tablet press machine allows you to identify defects early before they cause damage that can be costly.
Early identification will enable you to intervene soon, saving you plenty of production time and money in many cases.
Regular inspection also catches areas with the most wear and tear, allowing you to earmark them for replacement.
Additionally, with routine inspection, you identify parts that wear off faster than others allowing you to develop targeted mitigation strategies.
iii. Carrying out Repairs and Replacements
A repair procedure allows you to rehabilitate a damaged or broken part to a functional level.
When you replace a part, you write it off and procure a similar part to use in its place.
You evaluate articles of the tablet press that require repair or replacements depending on the level of damage.
Repairs are usually cost-effective in the short run; however, they don’t offer the same functionality level as replaced parts.
iv. Evaluating Precision of the Tooling System
In tablet making, you find the most sensitive part is the tooling system which conducts the compression process that forms tablets.
Setting the tooling system allows you to furnish tablets with a defined shape and dimensions via the punch and die system.
However, tablet making’s compression process is prone to high wear and tear due to the continuous movement and friction.
Consequently, the punch and die system can lose its precision levels resulting in inconsistent tablet formation if not checked.
v. Lubricating Machine Parts
Lubrication entails applying lubricants, which are soft and viscous fluids, to movable parts to reduce the impact of friction.
Friction is a force that resists motion resulting in accelerated wear and tear if not addressed.
You have many moving parts in a tablet press machine, such as the turret, punches, compression rollers and cam tracks.
Lubricating these parts ensures the effect of friction is minimal, thus reducing the rate of wear observed.
vi. Regulating the Storage Conditions
The storage conditions in your premises can affect the operation and life of your tablet press machine.
For instance, high humidity levels can increase the chances of rust building up in parts, causing increased wear conditions.
Alternately, high temperatures can affect the tooling system through expansion, hampering the kit’s precision levels.
Therefore, it is crucial to keep the storage conditions at a conducive state of cool and dry achievable by air conditioning.
How do you Troubleshoot a Tablet Press Machine?
When operating the table press, you encounter setbacks in the tablet making process that results in defective tablets or incomplete operations.
Sometimes, you remedy these setbacks by minor but effective adjustments to the machine, referred to as troubleshooting.
Common issues you can identify solvable by troubleshooting manoeuvres are:
High capacity tablet press
You encounter capping when ejecting a tablet from the die cavity, where it cracks on both surfaces.
Capping results from insufficient removal of air within the powder structure and die cavity during pre-compression.
Alternatively, your tablet undergoes capping upon awkward expansion that breaks up the tablet during ejection.
You can counter capping effects by lowering your speed of compression and resetting the punches involved in the ejection process.
Additionally, fine-tuning the sweep blade and polishing the punch and die system works well too.
You observe the lamination of tablets when they break along a horizontal plane of action.
Also, you credit lamination to the presence of air in the tablet structure, defective tablet ejection and high turret speed.
You can counter lamination defect by exerting slower force during pre-compression and main compression.
Besides, you can also employ a tapered die and regulate the turret speed to ensure the compression process is thorough.
When a tablet chips, you observe that after the compression process, its edges crumble.
A notable reason for this failure is the punch and die system’s mismatch and deficiency in machine programming.
You can remedy the situation by swapping the die system for new or conducting a reverse polish.
Examining the punches’ tips for breakages or bluntness is essential, replacing the former and polishing for the latter.
· Surface Cracking
You can develop cracks on your compressed tablet due to prompt and sustained expansion and using swift concave-shaped punches.
You address surface cracking by replacing the concave punches with flats, a tapered die system and custom tab ejection.
· Sticking of Material
Sticking occurs when the powder material clings to the tooling kit’s surfaces during the tablet making process.
Sticking indicates the presence of humidity within the die cavity or wetted powder material.
You need to rid your die cavity of moisture while ensuring the powder material fed to the tablet press is dry.
Adjusting the turret speed and increasing the exertion force and time during compression can also help squeeze out excess moisture.
· Double Tablet Impression
A tablet is doubly imprinted when the punch and die system’s compression acts twice in dissimilar positions.
A loosely positioned bottom punch typically results in a double impression due to its unrestricted movement.
You avoid double tablet impression by securing the punches in a fixed position devoid of any lateral movements.
What is the Difference Between B Tooling and D Tooling in Tablet Press Machine?
The TSM and EU standards guide the classification of tooling systems as B and D identities.
These descriptions help you identify the required punch barrel diameter and outer diameter for your die system.
Usually, the D tooling features a wider tip and barrel diameter compared to the B tooling system.
Furthermore, you can achieve different heterogenic classifications with the B and D tooling approaches depending on your needs.
You can combine the B classification to achieve a BB tooling identity.
Alternatively, you can use both the D and B tooling systems to develop an exceptional standard referred to as DB.
What is in a Factory Assessment Test for a Tablet Press Machine?
The Factory Assessment Test (FAT) ensures your tablet press machine meets the design specifications.
You confirm the worthiness of your machine to perform its expected functions by carrying out the FAT test.
FAT includes information such as:
- Technical parameters of the machine and its intended use and application.
- Operations or procedures of the tablet press under test.
- Procedural guide of running the tablet press machine and possible interventions in case of failure.
- Tablet press machine’s response to programmed information from the control panel.
- The machine’s response under stress conditions and how to address such.
- Machine consumption details when on standby and during operation.
What are User Requirement Specifications required for a Tablet Press Machine?
The User Requirement Specification is a useful document to your manufacturer when customizing your tablet press machine.
Consequently, you have to include whatever aspect of the tablet press you need to your specification.
Some of the information you provide in your URS include:
- A general description of your tablet press machine and how you would like to use it.
- Specifications regarding the size of your machine and the desired production capacity.
- Your preferred technical specifications include the achievable speeds, the turret rotation per minute, and exerted compression force.
- The machine ratings such as amperage, voltage needs and power.
- Your intended operational protocols and procedures for the tablet press machine.
- Where you have acronyms, you need to provide full meaning to avoid confusion.
- Schematic diagrams for your tablet press machine and electrical circuit presentations.
- An informational booklet for the benefit of other users.
- A list of required spares to come along with the tablet press machine.
How do you Test the Quality of Tablets Formed by the Tablet Press Machine?
Tablet hardness tester
Testing the quality of tablets made by your tablet press machine ensures you provide durable and worthy products.
Furthermore, you can identify failings with your tablet press machine where you establish issues with quality.
You need specialized instruments to help you test the quality of tablets made by your tablet press machine.
There are two possible tests you can carry, namely pharmacopoeial test and non-pharmacopoeial tests.
Pharmacopoeial tests for tablets seek to determine tablets’ effectiveness for pharmaceutical use such as medicinal drugs.
These tests probe the tablet for its constitution, consistency in weight, time taken to disintegrate and dissolution.
Non-pharmacopoeial tests include tests not querying drugs’ effectiveness when used for medical purposes but their physical aspects.
Some common non-pharmacopoeial tests include:
- Hardness test
- Tensile test
- Test for thickness
- Friability test
- Tablet disintegration tester
- Tablet dissolution tester
How do you set up a Multi-Tip Tooling Tablet Press machine?
Setting up a multi-tip tooling system is challenging due to the difficulty in aligning the multiple tips with the die system.
The multi-tip tooling system requires high precision levels to ensure the compression process occurs smoothly.
The installation process of a multi-tip tooling system takes the following approach:
Insertion of the punch brush is possible via the guides where you rid it of dirt, enabling a smooth insertion process.
Remember, you need to ensure your lubrication channel is connected to ensure the oiling of moving parts for smooth operation.
You introduce the cleaner for the die seat via the cavity side before initiating a rotation to eliminate unwanted material.
Also, you flush out dirt from the cavity and the press machine’s turret section.
Remove the top punch plates in the tablet press machine before carefully replacing them with a multi-tip device.
Thereafter, urge it forward cautiously into the die section suing a tool key for punch alignment and preload.
You achieve correct alignment when the tips make a clean entry and exit into the die cavity when prodded.
Alignment is vital as it ensures your tablet making process is unhindered and consistent.
You find an insertion ring for the die convenient in determining the correct installation of the die system.
You run the ring over the turret and simulate rotation while subjecting the top side punch to a force.
The rotation has to be smooth despite the applied force on the punch to indicate a perfect alignment.
Where you hear a click as the turret rotates symbolizes an issue with the alignment requiring intervention.
After addressing the misalignment issue, you position a lock screw in the tooling booth.
You need to attach the lock screw such that it connects with the die in a fixed state.
Thereafter, install the bottom punch and align it with the respective top punch, gently rotating the kit and strengthening the retainer.
The retainer holds the top and bottom punches firmly in position.
Ensure the retainer is not too tight as it can have adverse negative effects.
An overly tight retainer can hinder the performance of and even damage parts such as the cam tracks and turret.
What is the difference between Main Compression and Pre-Compression?
The compression process is the focal tablet making process in a tablet press machine.
When the powder material enters the die cavity, compression by the cam-controlled punches results in tablet formation.
The compression process occurs in two phases where you have pre-compression and main compression.
Pre-compression precedes the main compression and uses lesser force in its execution.
Pre-compression entails the removal of air from within the powder material structure and die cavity.
Air presence in the powder structure can affect tablet quality, resulting in cracking and lamination defects.
The primary compression process results in the formation of your tablets in the desired shape and size.
Here, you subject the powder in the cavity to enough force via the punches bonding the material into a tablet.
What is Turret in a Tablet Press Machine?
You find turrets in the multi-station or rotary tablet press machines where they support the multiple tooling stations.
The turret is a tool capable of rotation and designed to hold multiple punch and die systems.
An important aspect you find with the turret is alignment, where any slight misalignment affects the entire tooling system.
You identify three sections of the turret related to its configuration: the upper section, lower section, and die table.
The turret’s upper and lower sections support the top-side and bottom-side punches, respectively, while the die table contains the dies.
While many tablet press machines have fixed turrets, you can have an interchangeable turret.
With an interchangeable turret, you can automatically swoop between different turrets with different tooling station designs.
Consequently, you can use a single tablet press machine to produce tablets of different sizes and shapes without expensive upgrades.
Can you Customize Tablet Press Machine Tooling System?
You can always customize the tooling system for your tablet machine to suit your production needs.
You use a User Requirement Specification (USR) document to inform your supplier on whatever aspects you desire to customize.
In coordination with the product designers and engineers, your supplier evaluates your specification to determine its viability.
You get informed on any design limitations until you settle on an agreeable and executable design.
What is the difference between Tablet Specification Manual (TSM) and Euro Standard (EU)?
TSM vs EU
TSM vs EU Tooling
The TSM and EU standards provide guidelines for the categorization of tooling systems for the tablet press machine.
These standards are useful as they ensure your purchases have dependable tooling designs for your intended use.
You find the following differences between the TSM and EU standards:
- The punch heads in the TSM have an angled profile, whereas those in the EU have a domed punch head profile.
- For a B classification in the TSM, you have the inside head at a 37-degree angle. Alternately, the corresponding angle in the EU is 30 degrees.
- The overall head size in TSM is thicker compared to the slimmer head in the EU. However, the punch length in the EU is longer than that on the TSM by 0.010 mm.
How is Compression different from Compaction in a Tablet Press Machine?
When making tablets using the tablet press machine, you subject powder material or granules to compression forces to form them.
You find the punches controlled by the cam tracks essential in providing the compressional force required in the process.
Compression is in two phases, pre-compression which eliminates air particles in the powder and main compression, which creates the tablet.
You create a tablet by the action of compaction made possible by the applied compression forces.
During compaction, the powder particles bond under the applied compression forming a highly cohesive lump.
You, therefore, define compaction as the bonding action fostered by the compression force the punches initiate.
How does the Manual compare to the Automatic Tablet Press Machine?
Manual tablet press
Fully automatic tablet press
A manual tablet press machine is one whose multiple operations heavily depend on human control.
Automatic tablet press machines have their operations controlled by Programmable Logic Controls (PLC) or via a Human Machine Interface (HMI).
Manual tablet press machines fetch lower prices when compared to their automatic counterparts.
However, using manual tablet press machines for large-scale production is challenging regardless of the cost savings.
You, therefore, viably employ the manual tablet press machine for tasks with low output demands, such as producing samples.
Furthermore, you find using a manual tablet press machine to be simple with a manageable maintenance cost.
On the other hand, automatic machines attract a high maintenance cost, requiring electrical power to run and skilled labour to operate.
However, automatic tablet press machines are faster and more efficient in the production of large volumes.
Additionally, when you use automatic tablet machines, you can control operation speed, such as feeding and compression.
Consequently, you can comfortably adjust your machine when dealing with tablets of varying sizes and shapes.
When you employ automatic tablet press machine models, you incur lower labour costs in the long run.
However, you might need to train available labour in operation and troubleshooting of such machines.
Importantly, when working on large production batches, you find the automatic tablet press machine especially useful and cost-effective.
With only a few personnel, you can easily manage the output, unlike the manual equivalent, which will involve several persons.
Conclusively, you find both the manual and automatic tablet press machines with certain advantages and limitations.
The choice of selecting one or the other lies in your needs and financial capability.
What Design Aspects Affect the Efficiency of Tablet Press Tooling System?
By now, you know the tablet press machine’s tooling system is the heart of the tablet making process.
Consequently, you focus on elements concerning the tooling system as it determines your press machine’s operational effectiveness.
You find the tooling design influences the following aspects of the tablet:
- Desired tablet shape and size
- Intended hardness and thickness, which influences the compression forces applied on the plunges.
- The weight of the tablet, determined by the capacity of the die bore.
Common aspects of the design of the tooling system that influence its effectiveness in performance to achieve the aspects mentioned above include:
- Configuration of the punch and die system.
- Head flat of the punch.
- Top punch head’s incline angle, back angle and radius.
- Punch barrel and die cavity diameters.
Why are Tablets made by Tablet Press Machines Popular?
Tablets made possible by tablet press machines find varied use, especially in dosage administration for medical purposes.
The tablet making process requires close regulation with carefully set standards to ensure its reliability.
You can credit the popularity of tablets to the following factors:
When used for medical purposes, tablets provide practitioners with a simplified way of measuring dosages due to their high accuracy.
Determining the content of a single dose is easier with tablets compared to liquid formulations.
Simplified Manufacture, Packaging and Transport
The manufacture of tablets is cheap, requiring few production costs, especially when using an automatic tablet press machine.
Furthermore, you can package many tablets in a single container due to their compact nature earning you cost savings.
You do not require special vehicles to transport tablets, and you can use regular transport vans.
Other dosages such as those in liquid form may require refrigeration which increases the transport costs.
For pharmaceutical and nutraceutical tablets, you find their stability concerning chemical composition and material is unchanging, unlike other dosage kinds.
You can improve the stability of such tablets via coating procedures without affecting the excipients used.
Accordingly, you can keep tablets for longer periods without their deterioration.
Contrarily, dosages in other forms such as liquids and capsules have shorter shelf lives.
You can present tablets in various ways to increase their appeal without incurring high costs or distorting their content.
Additionally, you can improve the taste and smell of tablets by coating them to ease their uptake.
When you use tablets for medicinal purposes, you can contain a higher dosage concentration in a single tablet.
You cannot attain such concentrations when using other dosage forms such as capsules.
Furthermore, where you need a dosage fewer than those in a single tablet, you can break the tablet into parts.
It is difficult to downsize a capsule’s dosage where a single capsule has more than is required.
Different Forms of Uptake
You can take a tablet in different ways other than swallowing as you only would with a capsule.
There are tablets you can dissolve in water before drinking and those you can chew much like candy.
Why should you Coat the Tablet Press Machine Tooling?
Coated and uncoated tablet press tooling
You sometimes encounter several defects in the tablet making process due to the shortfalls of the tooling system.
For instance, you can experience sticking and picking, which occur on the punch surface resulting in a slump in tablet quality.
The attachment of material fragments on the surface of the press punch demonstrates sticking.
Alternatively, the implantation of particles upon the design impressed on the head of the punch exhibits picking.
Polishing and coating the press punch reduces the chances of defects such as sticking and picking occurring on your tooling system.
You use a well-mixed lubricant in the coating procedure to ensure it is effective in preventing such deficiencies.
What is Tablet Hardness when using Tablet Press Machine?
Tablet press machine
Tablet hardness defines the rigidity or toughness of a tablet you produce using a tablet press machine.
Your tablets’ hardness can vary depending on various factors centred on the tooling system and powder material structure.
When making tablets, you ought to achieve a defined hardness level that exhibits physical consistency as it undergoes other processes.
When you have a soft tablet, it is likely to succumb to defects such as chipping.
Furthermore, executing other tablet processes, such as coating and packaging, is challenging due to the weak tablet structure.
You need to ensure your press system is well set before the tablet making process to prevent hardness inefficiency.
You achieve tablet hardness by especially monitoring the following aspects:
i. Regulating the Weight
The tablet press tooling system works in the fashion you set every time it presses powder into a tablet.
You find an attribute causes of variation to the powder material to differences in the amount used for a tablet.
The hardness of your tablets will vary with their respective weight, given the same pressing conditions.
Usually, you have an intended weight for your tablet as per your specifications or requirements.
Consequently, you find having a tablet weighing lower than the desired level results in a softness, whereas the opposite is true.
You control your tablet weight by ensuring the amount of material allowed in the cavity is equal at all times.
ii. Maintenance of the Scraper Blade and Fill
When you fill the die cavity with powder material, you use the scraper blade to level off any excesses.
You should maintain your blade at a sharpness level that ensures consistency in the die fill’s material amount.
The nature of the material used for tablet making defines the level of wear on the scraper blade.
Wear is slower with soft powder material but accelerated with coarse and granulated material.
Does Dwell Time Affect Tablet Making when Using Tablet Press Machine?
You define dwell-time as when the head of the press punch and the compression rollers are in contact.
Furthermore, you express dwell-time as the contact time when the applied force exceeds ninety per cent of the required compression force.
You find the material composition of the tablet formulation influences the dwell time required to furnish a tablet.
When your material has a weak bonding structure, you need more time under compression force to achieve the desired hardness.
Employing adequate dwell time while making a tablet ensures you prevent tablet inadequacies such as sticking and picking.
Accordingly, dwell-time greatly influences the tablet making process when using a tablet press machine.
At SaintyCo, we design and manufacture high performance and reliable tablet press machines.
Depending on your unique requirements and specifications, we will help you find a perfect tablet press machine.