One of the main benefits of a rotary tablet press is the ability to produce tablets at a high speed. They also ensure precise control over hardness, thickness, and weight of the tablets. As a result, the end result will be perfect at all times. The latest rotary tablet press machines come with in-built quality control methods too.
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The main component of a rotary tablet press machine is the rotating turret. It is capable of holding a large number of dies³ and punches at the same time. They will compress and shape powder granules to create tablets in consistent weights and sizes. While rotating continuously, the turret will punch powder to create tablets. Here’s a detailed overview of how the process looks like.
The very first step is to fill the tablet press machine with granular or powdered particles. From the loading hopper, this material will flow to the frame. Frame is nothing but a force-feeding device. It is capable of distributing the materials evenly into cavities.
This stage will ensure that there is current amount of dosing material available within the cavities. It will ensure uniform composition and weight of tablets at the end of the day.
Step 3 – Compression
Compression happens in two different steps. The first step out of them is pre-compression. This is where the upper part will apply moderate pressure to the material inside die cavity. It will create a slug. The slug will function as the foundation behind main compression process. It will remove the possibility of having air pockets or voids within the tablet.
The main compression process swill shape the tablet into its final form. It will also ensure proper density, thickness, and hardness of the tablet. You will be able to adjust them according to the preferred characteristics of the tablet.
The final step is to eject the tablets. They will get into a tray in a gentle manner with the help of lubricants. As a result, you can make sure that the tablets will not encounter any form of damage. The advanced tablet pressing machines are capable of quality control as well.
Let’s take a look at the main components you can find inside a rotary tablet press machine:
While using a rotary tablet press machine, you are responsible for regular cleaning of it as well. It will help you with maintaining overall hygiene. To begin cleaning, you need to unplug the machine from power. Then you need to remove all the granules. With the help of a 95% ethanol solution and a paper towel, you can clean all parts of the machine.
To access the upper punches, you may disassemble it from the door on right hand side. Then you can unfasten all die locks with an alley key. By spinning the shaft, you may clean all the access ports. Optionally, you can proceed to clean the die boreholes as well.
In a single punch tablet press, you can find only one tooling station. It will have a die along with upper and lower punches. You will be able to operate this type of a tablet press machine manually or by power. However, it will not be possible for you to produce tablets from different materials. For that, you will need to use a rotary tablet press. A rotary tablet press even allows you to adjust the filling depth, rotation speed, and thickness of the tablet.
A variety of industries use rotary tablet press machines. However, pharmaceutical industry holds a prominent place out of them. Pharmaceutical companies use these machines to produce vitamins and tablets. Some other industries that use rotary tablet press machines include herbal, confectionary, and cosmetics.
This refers to a tablet press station that comes along with more than one punches and dies. By using a multi-station tablet press machine, it will be possible for you to manufacture hundreds of tablets at a time. Hence, manufacturing plants with a high demand for their products consider going for this option.
Compression force is the factor that rotary tablet press machines use to control weight of counting tablets. The gap that exist in between rollers exerting pressure will ensure uniform weight distribution within the tablet. On the other hand, the manufacturers can pre-determine the pressure, thickness, and hardness of the tablet.
The key components that exist within the rotary tablet press machine will determine its overall production capacity. They include lower punches, upper punches, and the die. Moreover, rotation speed can also create a significant impact on the overall production capacity.
Apart from the core components, there are many supporting equipment that you use along with a machine. They include:
While operating a rotary tablet press machine, you can encounter errors. Here are some steps that you can follow to troubleshoot those errors.
It will happen due to not having sufficient lubrication on the wheel. Hence, make sure to lubricate the pressing wheel at all times.
This also happens due to lubrication issues. Before operating the rotary tablet press machine, you need to lubricate and air compress it.
You need to use an air compressor and remove dirt accumulated within the machine regularly. Otherwise, it can result in excessive wear out of components. Moreover, it will also slow down the overall production process.
This happens mainly due to the excessive wear and tear of feeder. You will need to adjust or replace the feeder to overcome this issue.
Pharmaceutical industry: used to compress drug powder into tablets to ensure accurate drug dosage and uniform shape. Commonly used in the production of medicines, nutritional supplements, vitamins, etc.
Food industry: tablet presses are used to produce nutritional tablets, chewing gum, instant foods, etc.
Chemical industry: used to press chemical raw materials such as fertilizers, detergents and other solid tablets.
Health care products industry: used to press various health tablets, nutritional supplement tablets, etc.
Laboratories and research institutions: small-scale production and experimental tablets.
The future of the global tablet press machine market looks promising with opportunities in the pharmaceutical and food markets. The global tablet press machine market is expected to reach an estimated $1.51 billion by with a CAGR of 9.5% from to . The major drivers for this market are rising demand for pharmaceutical and nutraceutical products across the globe and increasing need for efficient and advanced tablet manufacturing processes.
Data Source：https://cn.gii.tw/report/luci-tablet-press-machine-market-report-trends-forecast.html
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When purchasing a rotary tablet press machine, there are some tips to keep in mind. Let’s explore them in detail.
Now you have a clear idea of how a rotary tablet press machine works. If you are planning to get a one, make sure to do it from a reliable vendor that you can always rely on. Then you can experience all benefits that come along with it.
1.Ketterhagen W R. Simulation of powder flow in a lab-scale tablet press feed frame: effects of design and operating parameters on measures of tablet quality[J]. Powder Technology, , 275: 361-374.https://www.sciencedirect.com/science/article/abs/pii/SX
2.Murray, F. J. (). Tablet Press Automation: A Modular Approach to Fully Integrated Production. Drug Development and Industrial Pharmacy, 22(1), 35–43. https://doi.org/10./
Selecting the right tablet press is a vital part of the pharmaceutical manufacturing process. The choice of tablet press not only affects the quality of the product, but also relates to production efficiency and cost control. Especially with the continuous progress of pharmaceutical technology, choosing the right equipment is especially important. In this article, we will talk about the key points that you need to pay attention to when choosing a tablet press, and you will find the answers to all the questions you have in your mind about choosing a tablet press in the following article.
The selection of a tablet press should start from your production needs. Specific production capacity, product characteristics, and quality requirements will determine the type of machine you choose.
How many tablets do you need to produce per day? This number is the most important basis for your tablet press selection. If your production line has a high daily output, you need a tablet press that can produce tablets quickly and efficiently, probably a high-speed rotary tablet press. Whereas for small batch, multi-species production or at the experimental stage, a single punch tablet press may be sufficient.
The tablet specification and material characteristics of the product will also affect the choice of equipment. If there are various tablet specifications, you need to choose a tablet press with strong mold compatibility. Different material characteristics may also require different parameters such as pressing pressure and speed.
What are the requirements for tablet weight, hardness, disintegration, etc. in your production line? These factors directly affect the technical parameters of the equipment. For example, if your tablets have strict requirements for hardness and disintegration time, you need to choose a tablet press with a more adaptable pressure range.
There are mainly single punch tablet presses, rotary tablet presses and multi-layer tablet presses available in the market, which have different applications, advantages and disadvantages.
Single punch tablet press is the simplest type of tablet pressing equipment, which works by applying pressure in the mold through an upper punch and a lower punch to compress the material filled in the mold into tablets. This type of machine is usually small and easy to operate and is suitable for small batch production on a laboratory scale or for product development in the pilot stage. However, the productivity is relatively low as only one tablet can be pressed at a time.
The rotary tablet press is the main tablet production equipment in the production line of the pharmaceutical industry today due to its high speed tablet production efficiency, which is characterized by the possibility of using multiple punches to press tablets at the same time. The main structure is that the upper and lower punches are mounted on a turntable, and as the turntable rotates, each punch goes through the processes of powder material filling, material pre-pressing, main pressing into tablets, and tablet discharging. High-efficiency continuous tablet production can be realized by the turntable drive, which greatly improves the efficiency of tablet production. Rotary tablet press is suitable for large-scale industrialized production, and the pressure size and tablet thickness can be adjusted as needed to meet the requirements of different materials.
There are many factors affecting the output of rotary tablet press machine, mainly including the following aspects:
Rotary speed: The faster the rotary speed, the more tablets will be produced per unit of time.
Number of Punches: The greater the number of punches, the greater the number of simultaneous tablet presses and the higher the output.
Punch Stroke: The longer the punch stroke, the longer the tablet pressing time and the lower the output.
Powder Flow: The better the powder flow, the more uniform the feed, the more stable the tabletting process, and the higher the output.
Material moisture levels: Both high and low moisture content can impact the quality of the tablets, thereby affecting the final yield.
Particle size: Particle size distribution is too wide or too fine will affect the quality of tablets, particle size distribution is uniform, particle size is moderate, the best effect of tablets.
Material Viscosity: Too much material viscosity will easily lead to the sticking of the punch, which will affect the output.
According to different output and tablet size, you can choose different types of tablet presses:
Multi-layer rotary tablet press is a tablet pressing machine that adds multiple feeders to the rotary tablet press so that it can form multi-layer structure tablets in one pressing process. This technology is mainly used for the manufacture of tablets containing different ingredients or having an extended release effect. In a multilayer rotary tablet press, the material is filled into the mold in a predetermined sequence through different feeders and then compressed in one or more steps to form the final tablet product. Multi-layer tablet compression technology can improve the bioavailability of the drug and control the release rate of the drug to achieve better therapeutic effect.
A tablet press with a high degree of automation can reduce manual operations, increase productivity and reduce error rates. The automated control system can also help you monitor and adjust the weight, pressure and other parameters of the tablets in real time to ensure the consistency of the product. However, highly automated equipment has a higher initial investment and is suitable for companies with higher production demands.
When choosing a tablet press, the key technical parameters will directly affect the performance and production quality of the equipment. You need to consider the following aspects according to the requirements of the tablet production process, the nature of raw materials, the size of the production scale and other needs:
The tabletting process requires different pressure ranges for different materials and tablets. The maximum and minimum pressures of the equipment must be in accordance with the characteristics of your material, otherwise it may result in substandard tablet hardness or disintegration time. Therefore, before making a purchase, be sure to check whether the pressure range of the equipment can meet your production needs.
The tablet pressing speed of the equipment directly affects the production efficiency, which is usually measured by the number of tablets pressed per minute. If you have a large production load, you need to consider choosing a high capacity machine. Rotary tablet presses are faster due to their ability to press tablets at multiple stations simultaneously, while single-punch tablet presses are suitable for a lower production tempo.
If your production line needs to produce tablets of many different shapes and sizes, die compatibility will be the deciding factor. Choosing a tablet press that can accommodate a wide range of dies will help you reduce die changeover time and increase production flexibility.
The stability and reliability of a tablet press is an important factor in guaranteeing the quality of the tablets produced. Choosing a reliable machine can help you to produce high quality and stable tablet products, and moreover, it can reduce the failure and downtime, so as to improve the production efficiency.
Choosing a tablet press brand with a good reputation usually means higher quality equipment and better after-sales service. Well-known manufacturers usually offer longer warranty periods and faster technical support so that you can get your equipment problems solved in a timely manner.
Prompt after-sales service can reduce downtime due to equipment failure. You need to make sure that the manufacturer can provide sufficient supply of spare parts and technical support to ensure the long-term stable operation of the equipment.
When using a tablet press for a long period of time, the maintenance cost is a key consideration for you. Certain equipment, although less expensive to purchase, may not be cost-effective to use in the long run if the maintenance cost is high. Therefore, it is important to know how often and how much the equipment will cost to maintain before purchasing.
Compliance of tablet press with GMP is an important guarantee to ensure the quality of drugs, meet regulatory requirements and enhance corporate image. It is a series of quality management norms that must be strictly adhered to in the process of drug production.
GMP standards require equipment to be designed with the ability to prevent contamination, such as dustproof design during tablet pressing. This not only ensures the quality of your drug product, but also saves you time in cleaning and maintenance.
Components that come into contact with pharmaceuticals should be made of stainless steel that meets food-grade or pharmaceutical-grade standards to ensure the safety of pharmaceuticals and compliance with relevant pharmaceutical regulatory standards.