AIPAK rotart tablet press
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A rotary tablet press is a mechanical device composed of several tooling stations that rotate in order to press the granules, powdery mixture to form a tablet of uniform size, weight, and given shape.
Rotary tablet press is developed to meet the real-time production of tablets. This machine is designed to support optimum conditions essential for quality production of tablets, such as:
Rotary tablet press is applicable in various industrial units including, pharmaceutical, nutraceuticals, cosmetics, foods, confectionery, and much more. The following manufacturing units require higher tablet production that’s why the rotary tablet press is the suitable and preferable option. Rotary tablet press yields a high-profit margin due to a high productivity ratio with minimal labor that ultimately meets up high demands for the tablet dosage form. Hence, this machine is of prime importance if you want to become a successful competitor among all pharmaceutical or relevant companies.
The working principle of a rotary tablet press is extremely simple that involves hydraulic pressure or application of pressure.
Tablet mixture or granules are packed into Die cavity followed by applied pressure with the help of punches such as upper punches and lower punches.
Rotary Motion- Working principle of rotary tablet press
One wheel or main roller is located on the upper side of the upper punch and one wheel or main roller is present below the lower area of the lower punch.
When compression is applied, the pressure of both punches is transmitted on filled powders into a die cavity and this transforms powders or granules into the form of a tablet.
The stages involved during this process are :
1.Filling
The filling is the first stage of tablet compression. In this stage, filling material is packed into the die cavity. The estimation of filling weight can be achieved by a lower punch in the die.
To ensure filling material is completely loaded into the die cavity, powders or granules are overfilled. Powder or granules from the hopper is introduced into the feeder. From feeder powders or granules are loaded into the die cavity.
Filling- Rotary Tablet Press
2.Metering
This is the second stage of tablet compression, where weight is adjusted according to the specification of tablets mentioned in the manufactured Batch record.
An excessive material is removed from tail over die that clears the extra granules when a lower punches cross over the weight adjustment cam. Thus, the weight of a tablet is determined and adjusted by rotating the knob connected to the shaft of the weight adjustment cam. A knob rotation can be done either clockwise or anti-clockwise.
An illustration of Rotary Tablet Press
On one side, the weight adjust cam turns upward that lift the lower punch in Die cavity thus filling space get lowers and the weight of the tablet also gets lower as fewer granules are loaded in less space.
While in the opposite direction lower punch moves down in the cavity that rises the space in the die cavity, so the weight of a tablet is also improved.
3.Compression
The third, and most important stage is compression. Because in this stage, powder or granular mixture is encounter to compression to form a tablet dosage form.
Compression- Rotary Tablet Press
As we mentioned earlier, the compression is applied using two main rollers, for e.g., upper roller and lower roller.
So, when punches come closer and pass-through spaces, pressure is transmitted to granular or powdery material to form a tablet.
This pressure also helps in determining of hardness and thickness of the tablet.
The lower wheel is connected to a knob and moves up or down by rotation of knob clockwise or anti-clockwise direction.
4.Ejection
Ejection is the fourth and last step of tablet compression. In this stage, an already formed tablet is ejected from the die cavity via lifting the lower punch with the help of an ejection cam. An ejected tablet is assembled into a tablet container using a discharge chute with help of take-off blades. A take-off blade is integrated into the backside of the feeder.
Ejection- Rotary Tablet Press
Filling- Compression- Ejection- Rotary tablet press
The rotary tablet press is a piece of ideal equipment that is valid for a wide range of industrial applications. For instance:
Rotary tablet press
1) Pharmaceutical Industry
No one can deny the importance of rotary tablet press in the development and manufacturing of pharmaceutical goods. Pharmaceutical industries extensively utilize rotary tablet press as a prime tool to achieve quality tablet dosage form in bulk production.
Rotary tablet press offers maximum tablet output such as to more than 2, tablets per hour. That’s why a rotary tablet press not only saves your time, but it meets up high production demands for tablet dosage form required by a large healthcare sector such as hospitals, clinics, pharmacies, etc.
A rotary tablet press is a compact machine that allows smooth and fastest production line with many unique features that has ability to run a large-scale tablet production.
Additionally, a rotary tablet press competes with other machines due to higher automation, superior consistency, and offering much larger presses, and reduced downtime.
2) Nutraceutical Industry
This is well- known that the manufacturing of nutraceutical tablet dosage form is not only challenging but time consuming and expensive process.
Because the formulation of nutraceutical products is different from pharmaceutical products that involve the incorporation of sensitive material such as vitamins, minerals, sometimes sticky substances, etc.
This job is perfectly done by a rotary tablet press.Do you know how?
The entire construction of the rotary tablet press is made up of stainless steel. Also, unique features, rapid production under a safe and hygienic production environment yields quality outcomes to end-users.
3) Food and Confectionery Industry
A rotary press tablet machine is a reliable machine that is perfectly suited for the application of food and confectionary items have been in high demand for the last few years as this machine offers exceptionally robust patterns and designs.
You can manufacture carbonated soda tablets, fruity flavor tablets, chocolate tablets, and much more. This is the safest mode of machine that will make your manufacturing production line extremely quicker and consistent. That’s the reason every food and confectionary industry prefer rotary tablet press as a first choice for tablet manufacturing unit.
For example, chicken or stock cubes, sweeteners for diabetic patients, fructose, or dietary supplements.
4) Cosmetic Industry
The cosmetic industry is intended to use rotary tablet press for the manufacturing of skincare products. For instance, bath tablets, bath salt, or bubble bath. Rotary tablet press has the capability to compress those granules or mixtures that are difficult to compress or require special manufacturing compression. Furthermore, skin care products strictly adhere to the principles of GMP and quality assurance. Thus, all these requirements are fulfilled by using a rotary tablet press.
Bath Salt Tablets- Rotary tablet press
5) Sintered Metal, Ceramic, and Electrics
A rotary tablet press is suitable to deal with compressing hard metals or those substances that are difficult to compress.
Because their special Tooling system offers a wide range of metal compression power that is suited for dealing with abrasive substances.
Sintered metals are broadly used for the manufacturing of automobile parts. These are strong metals most often available in the form of compact tablets.
For which their manufacturer demands rotary tablet press that is capable to compact the metal sintered powder into metallic tablets. Similarly, many ceramic and electric manufacturing industries use rotary tablet press for the compression of ceramic, hard metals and coal, etc.
Hence, the rotary tablet press is also one of the most important manufacturing tools require for this purpose.
Coal Tablet- Rotary tablet press
Zinc Sulfide Sintered Tablets
6) Veterinary Industry
Rotary tablet press is of prime importance when dealing high production demand for veterinary tablets. A rotary tablet press supports the veterinary manufacturing sector and easily fulfills the ongoing medicinal requirement (pet animals, farmers, poultry, etc). Rotary tablet press can perfectly assess the product behavior, measurements, and quality to deliver safe and potent veterinary medicinal goods.
Veterinary Tablets- Rotary tablet press
7) Chemical Industry
The manufacturers of the chemical industry necessitate rotary tablet press for manufacturing chemical tablets. There are many chemical hazardous, irritant, and corrosive in nature substances that are available in tablets form, such as sodium hydroxide, acidic buffers, etc.
You might be wondering about their manufacturing because they are available in accurate doses with a uniform physical appearance.
A rotary tablet press can do this job efficiently. That’s why a rotary tablet press is considered essential equipment to deal with chemical substances with the safety and security of the operator and environment.
Based on production capacity rotary tablet press offers an accelerated tablet formation with reduced chances of chemical interaction and errors.
Chlorine tablets- Chemical Industry- Rotary tablet press
8) Agriculture Industry
Rotary tablet press is suitable equipment for manufacturing agricultural products such as pesticides, growth-promoting tablets, etc.
This machine has the ability to optimize the product feeding system for sticky or non-free-flowing products. Hence, rotary tablet press can perfectly manufacture and deliver different types of substances in tablet form to promote agriculture requirements.
Few important components of rotary tablet press are given below:
1.Hopper
Hopper is the channel in which dry powder is stored; this powder will be compressed into a tablet later.
2.Fill Tray
The function of the Fill Tray is to transfer dry powder into the Die bore and to drive the tablet in the Ejection Chute.
3.Die
Die is the channel that holds the powder, and then powder is squeezed to form a tablet. This channel can control two factors
Punching Die- Rotary tablet press
4.Upper and Lower Punch
Upper Punch is pressed downward and puts pressure on powder so that it can be squeezed into the tablet. Lower Punch stores powder and also apply pressure on powder. After the tablet is created, a lower punch is forced upward to remove the tablet from the Die.
Rotary Tablet Punches
5.Turret
In this component of the machine Tooling components (Die, Upper, and Lower Punch) are placed.
Turret- Rotary tablet press
6.Upper and Lower Tracking
Movement of the Tooling components is directed by upper tracking and lower tracking.
Upper and Lower Tracking
Upper and Lower Tracking
7.Upper and Lower Pressure Cam
The pressure to drive upper punch and lower punch downward and upward respectively is supplied by Upper-Pressure Cam and Lower Pressure Cam. These two-pressure cam force upper and lower punches to condense powder and form tablets.
8.Lubrication System
Nowadays modern rotary tablet press machines have a built-in lubricating system that allows lubrication to those parts of the machine automatically that required after certain periods. Hence it will save your time and maintain the quality of the machine.
9.HMI OR Human Machine Interface
A rotary tablet press has a touch screen system that offers easy input of running data.
This is an easy-to-operate machine that allows feeding data by entering the instructions into the system and the rest of the job will be performed by an automatic rotary tablet press itself.
There are basically two types of rotary tablet press:
The main difference between single and double rotary tablet press is that you may use a mini-tablet press or single tablet press using single Tooling such as Die, upper and low punch.
Whereas, on the other side, a double-sided rotary or multiple-punch rotary tablet press is an extensive machine that requires various tooling systems to execute the process.
Single rotary tablet press is ideal machine for R&D, clinical and small-scale productions. It is also used to minimize the wastage when high value ingredients are applied for tablet formulations.
Single rotary tablet press is also recognized as lab tablet press machine.
A double sided rotary tablet press is a highly capable machine that delivers tablets in high acceleration and compression up to the requirement of the protocol.
Furthermore, it has a high-speed mechanical device for compression that has been developed for action of punches and dies. This machine is ideally chosen for large scale production units of various industries.
Single Rotary Tablet Press- Photo Credit- Tablet Press Company
Double-Sided Rotary Tablet Press
The installation of a rotary tablet requires few basic steps:
1) Unpacking:
The unpacking of the rotary tablet press should be done very carefully. As the machine is secured in a wooden pallet, so opening or unpacking the machine you must open the top of the case later move for sides of the case.
Always remember rotary tablet press should be dispatched with a toolkit separately.
Therefore, every received kit should be obtained first before unpacking the machine. After opening the box uncover the machine from the plastic covering.
ToolKit- Rotary Tablet Press
Unpacking Instrument- Rotary Tablet Press
2) Lifting
The movement of the machine may be done directly using the hook on the top of the rotary tablet press. Before moving the machine ensure eyebolts are fully cantered and at the right position. Life the machine straight and place it in the assigned position. This should be placed on a rigid stage/platform with 2 feet of height.
Pharmaceutical Machine Lifter
3) Levelling
Rotary tablet press should be mounted on anti-vibrational pads or platform. Most often rotary tablet press does not require any levelling. But smaller or lightweight machines may require adjustment, therefore, anti-vibrational pads must be used to adjust the machine base plate.
Excellent instrumentation of rotary tablet press meets all safety and practical standards of cGMP.
Separate Electrical Box (1. motor speed, 2. magnetic contactor & starter, 3. Breaker, 4. Fuses, 5. Terminal block, 6. Power relay)
Rotary Tablet Press
In order to have a fully operational machine that lasts long, it is essential that the maintenance schedule of the machine is kept. Greasing and cleaning of the machine are important parts of the maintenance procedure.
General Maintenance
Lubrication
The machines which are lubricated according to the schedule have operational life that lasts for a long time. It is vital to grease parts because they get stuck and affect the working of the machine. For proper lubrication follow these steps
1.First, uplift the Hopper part and unfasten four screws located at the top of Perspex Casting and release it.
2.Release upper and lower punches.
3.Grease the heads of Punches with grease.
Heads of Punches- Rotary tablet press
Upper Tracking- Rotary Tablet Press
Lubrication Schedule
Turret Bearing
During the working of the machine, the excess powder gets deposited into machine parts Tooling, Fill Tray, Turret, and Upper Tracking and then these parts get jammed.
So for the proper working of the machine, it is essential to clean parts of excess powder and debris.
Remove Part
Cleaning of Parts
Cleaning of Base and Turret
Base and Turret of rotary tablet press
Rotary tablet press is an extensive tablet pressing machine that has several advantages such as:1. High Production Output
A rotary tablet press is good and a powerful machine that yields quality product output that is hundreds of times greater than a single punch tablet machine.
This is an ideal machine for continuous tablet production that ranges from more than 200,000 high-quality tablets per hour. Therefore, this machine is recommended to run high production units of tablet manufacturing sectors.
2.Safe Production
The rotary tablet press utilizes upper punches and lower punches that create pressure. This pressure is mild and constant that can be easily discharged and reduces the chances of lobes phenomenon (instability or vibration during the process).
3.Stable and Low Noise
Rotary tablet press has adopted pressure rollers for rising of pressure. Furthermore, punches are firmly arranged in order to combat shock phenomena. These parts cumulatively allow stable and noise-free production.
4.Accurate Tablets Weights
Rotary tablets machine allows the production of tablets with accurate and uniform weights. It is comprised of a fixed feeder that has a long feeding time. Air can easily discharge with fewer chances of granules stratifications.
5.HMI
An HMI-based system of rotary tablet press easily manages the modulation of tablet hardness, thickness, and other important parameters necessary for tablets production such as speed, production per hour, etc.
Yes, Multiple punch rotary and rotary tablet press are the same equipment that follows the same working principle. The term rotary indicates the movement of upper punches, lower punches, and dies are around an axis in a rotatory motion.
As the head of the rotary tablet press moves, it simultaneously rotates associated parts that compress the tablet granules into a compact form.
Problems arise during the operation of the machine, which affects the production of tablets and also causes deterioration of machine parts.
There are several solutions by which these problems can be managed. You should be aware of the function of every component of the machine to solve these issues.
The most common issues are
1.Freezing and Locking of Rotary Tablet Press
Sometimes machine gets jammed or struck which affect the manufacturing of the tablets.
The possible reasons for this issue are
These issues are solved by frequently oiling the grease point and also the areas in which a huge amount of friction is produced. In order to release excess pressure, the pressure knob located at the left side of the machine should be rotated clockwise. For removing surplus powder you should take apart Turret and Tooling components and clean them.
2.Abnormal Sounds
Sometimes knocking sounds can be heard from the machine. This problem is caused by various reasons such as
The pressure knob present on the left side of the machine should be turned anti-clockwise for getting rid of excess pressure. Tauten the loose parts of the machine and get new V Belts to stop the knocking sounds. Also, you should inspect the level of the oil gearbox.
3.Encountering resistance during manufacturing
Every now and then the problem of resistance in rotary tablet press parts is encountered. This problem is because of force which is faced by machine parts that cause difficulty in their movement. Resistance arises due to:
This issue is solved by proper lubrication, oiling, and greasing machine parts especially in areas of high friction. You must also thoroughly clean each and every part of the machine.
4.Vibration in Machine
Sometimes you feel that your machine is producing excess vibrations which affect the production process. This problem is occurring due to the fact that
These issues are resolving by replacing V Belts and getting new anti-vibration pads. Anti-vibrations pads must be placed at the bottom of the machine. Inspect and tauten machine parts if they are loose.
5.Debris in Machine Components
Every now and then excess powder is stucked into machine parts and causes the jamming of machine parts. The powder is leaked in machine parts because of several reasons like:
These are solved by decreasing the rotation velocity of powder and also by adjusting the level of Fill Tray and Fill Tray Scrapers.
6.The powder is sticking on Upper Punch
When the powder gets stuck on the upper punch it can hinder the movement of the upper punch in the downward direction and affect the formulation of a tablet. This problem occurs due to
You should take out every part of Tooling and replace them, this will solve the problem. Also, check the formulation of a tablet as this may also cause sticking.
7.Broken or Shattered Pill
This is the most considerable problem which affects the manufacturing process. This also increases the time and cost of the production process. Various factors produce this problem such as
In order to solve these problems first, you should check the quantity and quality of ingredients and also check for the errors in the formulation. Alter level of Fill Tray and Fill Tray scrapers so that adequate material should be fed into Tooling.
8.Soft Tablets
Even now and then machine manufactures soft tablets or pill of inadequate weight, and these poor-quality tablets impact the cost of manufacturing. This issue arises because of
These issues are countered by checking the errors in the formulation and also, by moving the pressure knob found on the right side of the rotary tablet press in an anti-clockwise direction.
9.Tablets get cracked during ejection
Sometimes you see the tablets get broken when they are ejected from the Rotary Tablet Press. This is caused because of
These issues in the ejection cam are solved by taking out Turret and examining and cleaning the ejection cam. If the ejection cam is old, then you should replace it with the new one.
The rotary tablet press was invented first as the single punch machine that was only utilized to compress a single tablet each time. With demands and requirements, a rotary tablet press was developed that can manufacture many tablets in each round.
With time, various modifications, advancements have been established in the rotary tablet press to process more reliable, robust, and fast production.
The main factors for improvements are as follow:
Prime Advancement in Rotary Tablet Press
1) Vacuum Feeding
The tablet compression process begins with the filling of powders or granules in the hopper of the rotary tablet press.
Conventionally feeding of material into rotary tablet press was done manually, which results in cross-contamination, the risk for operator poor feeding, less volume, weight variation, etc.
Advancement
2) Rejection Mechanism
Due to weight variation, inconsistency, or hardness may occur.
In the old rotary tablet press, soft, low-weight, or inconsistent tablets were not removed automatically.
Advancement
3) Visual Monitoring
Visual monitoring such as the HMI system is utilized to improve the quality of the product. Abnormality in the weight or hardness does not give alerts.
Advancement
Any changes in the protocol can easily be made in a running system
4) Visual Alarm System
There was no concept of an alarming system in an old or conventional rotary tablet press machine.
Advancement
5) Metal De-Duster
In conventional rotary tablet press, tablets were passed through a separate de-dusting and metal detecting system that was indeed a time-consuming process. Additionally, this integrated system dictated a high production area.
An Advanced Rotary Tablet Press Machine with a Closed Housing Unit. Photo Credit- Korsch Tablet
Advancement
With the advancement in technology of rotary tablet press, now you can find both systems incorporated into a single unit that can efficiently perform de-dusting and metal detection tasks. Furthermore, this system does not occupy a larger space as well as energy.
6) Self-Maintenance
Up till now, you need to follow the weekly, monthly, and yearly maintenance protocol required for the machine. Therefore, it self-maintenance parameter is introduced in the rotary tablet press machine.
Advancement
Rotary Tablet Press Machine
7) Advancement in Tooling
There are multiple advancements in tooling system has been used such as:
A) Multi-Tip Tooling
As it names shows, multi-punch tooling is introduced
B) Exchangeable Turret
For a good quality manufacturing machine, you always seeking quality standards certifications that assure the machine is safe, robust, reliable, and perfect to meet your production demands.
A rotary tablet press is an ideal machine that meets all the basic quality standards assigned by international governing bodies.
1.cGMP Compliance
Rotary tablet press is considered as most trusted and demandable product for pharmaceutical, nutraceutical, food, and other healthcare units.
The basic make-up of this machine is done by stainless steel. Therefore, a rotary tablet press offers up-level sanitation and safety to end-user.
2.CE Certified
Rotary tablet press is CE certified equipment entails quality standards are regulated by European directives and regulations.
3.FAT test
Rotary tablet press is FAT verified equipment that entails machine is highly validated and capable to facilitates all working specifications to the end-user.
4.ISO Certified Machine
Rotary tablet press is suited to meet quality assurance and standardization parameters required for the manufacturing department of industry.
5.FDA Compliant
Rotary tablet press is FDA compliant machine that entails this machine is highly robust, effective, reliable, and safe without any false aspects.
If you are looking for more details, kindly visit bag packing machine.
Before buying a rotary tablet press you must consider the following important points that will help you to choose the right machine for your production unit:
Allpack Rotary Tablet Press Machine ZP-5B
Rotary tablet machine, also known as multi-station tablet press, is an electric machine created to compress powders and granules into tablets. The machine uses automatic technology to carry out this task in a way where the dry mixture is precisely poured into relevant die cavities, compressed hardly, and the formed tablets are ejected out of machine.
This machine is highly efficient in its production while taking care of dosage. It is made up of GMP's regulated stainless steel body and a protected window. Moreover, it is highly versatile in terms of manufacturing different types of tablets. That's why its significance is realized in almost every sector.
Doctor picking drug pack- Picture Courtesy: wolterskluwer.com
The presence of a rotary tablet machine is inevitable in pharmaceutical industry due to the nature of manufacturing in this field. This machine has gained a position of importance in pharmacy due to multiple reasons among with the prominent one is efficiency.
Rotary tablet machine produces thousands of tablets in an hour which make it possible to deliver required drugs to patients all around the globe. Another reason is the protection of medication mixture which is highly considered in pharmacy because minor mistake can ruin the effect of drugs. But here the machine is proficient in forming precise tablets.
Rotary tablet machine can be advantageous for you in multiple ways. Below highlighted benefits are some of the prominent ones:
Efficiency
Bilayer tablets discharging from machine- Picture Courtesy: ibermaticoss.com
Rotary tablet machine is known for its consistent working process which ultimately leads to the production of myriad of tablets in a single run. Hence, its efficiency can enhance your manufacturing output.
Safety
Drug safety presentation idea- Picture Courtesy: iStock
By using a rotary tablet machine, you will not be bothered to take the risk like manually intervening into the operation if spontaneous error occurs, rather pressing emergency button will stop the machine. Similarly, the protected body of machine is highly antibacterial that it safely processes the mixture without modifying its characteristics.
Convenience
Rotary tablet machine promotes user convenience due to its easy-to-use operation panel through which operator can communicate with the machine. Moreover, the machine does not require number of labours, but single user is enough to run the machine.
Resilience
Bilayer tablets- Picture Courtesy: europeanpharmaceuticalreview.com
Rotary tablet machine is highly resilient due to its capability to press eclectic sizes and shapes of tablets. Moreover, there is wide collection of rotary tablet machine models which enable you to form bilayer, multilayer, and effervescent tablets.
Reliability
Manufacturers look for cost-effective machines to cut the production costs of tablets. In this way, a rotary tablet machine is extremely reliable which requires low maintenance, single operator, and ultimately reducing the additional expenses.
All kinds of small to large with different sizes and shapes tablets can be made by a rotary tablet machine. Below is the glimpse of these all:
Single Layer Tablets
Patient holding single layer tablet in hand- Picture Courtesy: usana.com
Single layer tablet is a standard type of tablet where single Active Pharmaceutical Ingredient is delivered to patients. Such tablets are always perfectly formed by a rotary tablet machine.
Bilayer Tablets
Bilayer tablets- Picture Courtesy: Fette Compacting
As the name indicates, bilayer tablets are tablets containing two separate powered mixture compacted together. Their process of formation occurs in a way where first powder mixture is compressed and then second powder mixture is introduced over the formed tablets and compressed together. Such bilayer tablets can be easily made by a rotary tablet machine.
Multilayer Tablets
multilayer tablets- Picture Courtesy: bharatagritech.com
Multilayer tablets refer to the tablets having three distinct dosages compacted together. The purpose of making multilayer tablets is to provide three different Active Pharmaceutical Ingredients in a single tablet paving the way for effective drug delivery. Therefore, a rotary tablet machine is capable to form multilayer tablets.
Effervescent Tablets
Effervescent tablets- Picture Courtesy: solife.blog
Effervescent tablets are also called carbon tablets which are extra large in size than standard tablets. They are designed to quickly dissolve in liquid, therefore, most of the effervescent tablets contain calcium dosage and energy dosage. Here, it is pertinent to mention that a rotary tablet machine can be used to form effervescent tablets.
The working process of a rotary tablet machine is based on certain steps where a turret moves in rotary direction and lead the powder to turn into tablets. This process can be better understood in by reading the underlying explanation:
Filling
Powder Filling- Picture Courtesy: LFA Machines
The first step is filling where bulk powder or granules mixture is filled into the hopper of machine. From hopper, the powder flows to feeding unit known as feed frame. This feed-frame then evenly distribute the powders into each passing die cavity.
Metering
Powder Metering- Picture Courtesy: LFA Machines
The second step is metering which is also known as dosage or weighing. In this step, the precise amount of powder is weighed after which the lower punches move upward to remove excess powder from die bore.
Compression
Tablets compression- Picture Courtesy: LFA Machines
In third step, the upper and lower punches are brought together with force to form the tablets. The compression stage can be further divided into pre-compression and main compression.
In pre-compression, the upper punch descends to press powder with little force for creating a slug to remove air pockets. After this, in main compression, both the upper and lower punches are brought together with much force which result in the formation of uniform tablets.
Ejection
Tablets ejection- Picture Courtesy: LFA Machines
In last step, the upper punches move upward followed by the rise of lower punches in ejection can. Similarly, the tablets are ejected out of the die bore towards scrapper. The scraper then moves down the formed tablets down the ejection track into the container.
Rotary tablet machine consists of several components which together help the machine to form tablets making function. These parts are explained below in detail along with the main task each perform. So, consider the following description:
Components of Allpack ZP25 effervescent rotary tablet press machine
Hopper
Hopper is sometimes called the feeder system of a rotary tablet machine. You will always find the location of a hopper on the top side of machine. The number of hoppers depends upon the type of machine; however, the common hopper is one or two in number. It provides the machine with dry powdered or granulated mixture.
Stainless Steel Body
The body of the machine is compact and robust that greatly contributes to supporting a stable operation. It is made up of GMP's regulation stainless steel material, which is fully protected against bacteria and corrosion, therefore, material is processed inside it.
Rotary Table
Rotary table is the core component of a rotary tablet machine which distinguishes it from other types of machines. The table itself is made up of further parts including:
Turret:It is the vital part of a rotary tablet machine with round structure having multiple holes where dies and punches are adjusted. During tablets compression, this turret rotates and lead dies and punches to compress powder.
Punches:Rotary tablet machine has two punches; upper punch and lower punch. These are durable stainless steel rod type tools having on their tips or heads the specific shape. Punches are vital in compressing powders into tablets through exertion of force.
Dies:Dies are among crucial components of a rotary tablet machine. They are small round tools with a single or multiple grooves where the lower and upper punch meet in order to compress the powder into tablets.
Compression Rolls:Compression rollers are cylindrical rollers who perform the function of pressing powder. They are two in number including pre-compression rolls and main compression rolls. The former compress powder to remove air, while as, the latter exert excessive pressure to form tablets.
Cam Tracks:As the name indicates, cam tracks are tools which provide track for the synchronized movement of punches.
Organic Glass
Rotary tablet machine has a transparent protected window that enable the user to monitor tablets making process without touching it.
Operation Panel
Operation panel is a board containing touch screen display and certain knobs through which the user set commands in machine such as the quantity of powder for each tablet, the thickness of tablets, and compression force etc.
Emergency Stop
Emergency stop is a red colored large size button located on the front of a rotary tablet machine. It is a safety switch used to shut down the machine in an emergency.
Electric Appliance Box
It is consistent the most vital component of a rotary tablet machine where all the electrical components are collectively placed for supporting smooth functioning.
Adjusting Handle
Adjusting handle is used to modify the force of compression roller.
Discharge Chute
This part of machine is responsible to exit the formed tablets from machine into a collection container.
There are multiple types of rotary tablet machine available in market today. This wide classification has been introduced to meet the growing demands on part of manufacturers. So, let's explore these types in detail!
According to Automation
Automatic Rotary Tablet Press Machine
Automatic Rotary Tablet Press Machine
Automatic rotary tablet press machine is the most advanced form of rotary tablet machine. It is fully automatic in technology with production output reaching the figure of tablets per hour. This machine can be integrated with other machines to further enhance the efficiency.
Structure
The structure of machine is robust and complex which is an assembly of several small to large components. These include a stainless-steel body, transparent window, control system, electric enclosure, turret, hopper, punches, dies, compression rollers, and a touch screen penal.
Working Process
It is fully automatic, therefore, automatically dispense the powder from hopper onto feed frame and die cavities simultaneously. Afterwards, the pre-compression and main compression take places. At last, the formed tablets are removed out from die bores through ejection.
Semi-Automatic Rotary Tablet Press Machine
Semi-Automatic Rotary Tablet Press Machine
Semi-Automatic rotary tablet press machine is small design machine with good production capacity of producing tablets per hour. The machine is easy-to-use and cost-effective in price. Different small to medium size industries can take advantage of this machine.
Structure
The structure of machine is small made up of several components including a metallic base, stainless steel hopper, turret, control board, compression rollers, and a motor etc.
Working Process
The machine is manually loaded with powder formula and powered on. It then automatically fills the die cavities, compresses the powder and eject formed tablets from die bore and discharge into the laying container.
According to Sides
Single Sided Rotary Tablet Press
Single Sided Square GMP Mini Tablet Press- Picture Courtesy: deepujpharmamachinery.com
Single sided rotary tablet machine is a common type of machine with single hopper and single rotary table. However, despite being a single sided equipment this machine can give you excellent production rate of compressing to per hour.
Structure
The structure of machine is medium size compared to double sided rotary tablet machine. It mainly consists of a single hopper, one turret, operation panel along with certain knobs, and an electric appliance box.
Working Process
It follows the conventional working procedure by filling the dies with powder. Afterwards, precise amount of powder is kept inside the dies and rest is removed. The filled powder is then compressed to form tablets. When the punches reach to ejection cam track, the formed tablets are ejected from the machine.
Double Sided High Speed Rotary Tablet Press
Double Sided High Speed Rotary Tablet Press- Picture Courtesy: deepujpharmamachinery.com
This is another type of a rotary tablet machine which is tailored with excellent tools and double rotary punches to achieve utmost productivity. In this machine, the powder is fed into two turrets from double sides. Therefore, its production efficiency is double than a single rotary tablet machine with compressing 2,66,400 tablets in an hour.
Structure
The structure of machine is a composite whole of double turrets, two hoppers, four adjusting handle, enclosed body, control system, and electromechanical tools etc.
Working Process
It simply works in a way where one hopper is responsible to provide powder to the die cavities located in upper turret, while as, another hopper feed the die cavities of the lower turret. Similarly, both these turrets undergo compression stage and ultimately, discharge the compressed tablets through single discharge chute.
According to Layers
Bilayer Tablet Compression Machine
Bilayer Tablet Compression Machine- Picture Courtesy: deepujpharmamachinery.com
Bilayer rotary tablet machine is featured with innovative technology to form bilayer tablets by compressing two formulations into single tablet. It has high efficiency level and can be used in nutraceucal, pharmaceutical, and food industries.
Structure
This machine has relatively a precise body with several parts accounting for its construction including two funnels, single turret, pre-compression and main compression rollers, multiple adjusting handles, and electric enclosure etc.
Working Process
It works by infusing the first formulation into die cavities and compress them. The turret them move and leading these die cavities to be filled with second formulation. After this, the main compression exert force on punches leading the creation of uniform bilayer tablets. Finally, tablets are ejected from the dies.
Multilayer Tablet Press Machine
Multi Layer Tablet Press Machine- Picture Courtesy: deepujpharmamachinery.com
Multilayer tablet press machine is the most updated model of a rotary tablet machine with the ability to form three-layer tablets. It greatly ensures the precision of each dosage layer with the help of integrated sampling facility for weighing and checking. Moreover, it can be employed in food, medical, and chemical industries.
Structure
It consists of three hoppers, heavy-duty machinery, feeder system, compression rollers, emergency stop, turret, control panel, and discharge chute etc.
Working Process
The working process of a multi layer tablet machine is a bit unconventional with intermittent filling of powders into dies and their subsequent compression. Firstly, individual powder mixtures are poured in separate feeding hoppers. Secondly, when the turret start moving, one powder mixture is filled in die cavity and get compressed.
This die cavity is then filled with another powder mixture and compressed where two layers get formed. Thirdly, the same die cavity is then filled with distinct powder mixture and a final compression take place. Finally, the formed tablets are ejected and discharged.
Rotary tablet machine and single punch tablet machine are used for making tablets but their structure, working process, and many other aspects are different from each other. Therefore, we have explained these differences in the table below for your clear understanding:
No Factors Rotary Tablet Machine Single Punch Tablet Machine 1 Definition Rotary tablet machine is a multi station rotary press machine that compress powder with upper and lower punch. Single punch tablet machine is the earliest form of a tablet press machine with single punch. 2 Structure Its structure is complex and containing different components. While as single punch tablet machine is small in size and consists of fewer parts. 3 Number of punches It has set of upper and lower punch. On the other hand, this type of machine has only a single upper punch. 4 Process Its process is convenient due to automation but has several stages. In contrast, the working process of a single punch tablet machine is straight forward. 5 Speed It is highly efficient with capacity of producing 800 tablets in a minute. In contrary, this machine can compress 80 tablets per minute. 6 Cost It is expensive than a single punch tablet machine. While as, this machine is cost-effective. 7 PictureAllpack Rotary tablet press machine ZP-7B
Allpack TDP series Single punch tablet press
A rotary tablet machine has extensive applications which can be better understand by looking into the below highlighted sectors:
Pharmaceutical Industry
Coated oblong tablets- Picture Courtesy: tabletscapsules.com
Rotary tablet machine is widely used in pharmaceutical industry to meet the excessive need for producing different kinds of tablets and pills with varying shapes and sizes.
Nutraceucal Industry
Nutraceucal drugs display- Picture Courtesy: depositphotos.com
As the growth rate of nutraceucal industry is surpassing other sectors, it can be said that demand for formation of large number of tablets is also growing. Hence, a rotary tablet machine is inevitable to fulfill this production target.
Veterinary Industry
Doctor treating a dog- Picture Courtesy: stock.adobe.com
Tablet is considered the most convenient and desirable form of dosage which can be easily swallowed by pets and animals as well. Therefore, veterinary industry uses a rotary tablet machine to make abundant tablets.
Food Industry
Malt tablets packaging- Picture Courtesy: roscela.com
Among other areas food sector is the notable one. Here, you will find number of confectioneries in form of bilayer and multilayer tablets like milk tablets, chocolate tablets, and other tablets made from compacting salt and dyes. So, a rotary tablet machine can be used in various food industries.
Chemical Industry
Chlorine tablets in hand- Picture Courtesy: tennisamatoriale.it
The application of a rotary tablet machine can also be found in chemical industry where chemical powders are compressed to form tablets and then used for different purposes. In this way, chlorine tablets are the common example.
Pesticide Industry
Tree & shrub tablets- Picture Courtesy: marriedtoplants.com
We are familiar with the fact that the health of plants is always in danger due to harmful pests and insects. That's why different techniques have been employed to tackle this issue by restricting the access of these organisms to plants. Similarly, pesticides have been enclosed in tablets for which a rotary tablet machine is used.
In order to examine the quality of a rotary tablet machine, you can simply check the certifications of the company. In this way, below highlighted quality standards are internationally recognized ones whose compliance will indicate that the machine is made up of quality material:
ISO
International Organization for Standardization is an international organization established to ensure the credibility and safety of goods and products. Therefore, if a rotary tablet machine is ISO certified, it is made up of quality material.
GMP
Good Manufacturing Practices is yet another platform created to guarantee the hygiene and purity of a rotary tablet machine. So, a machine complying with GMP regulations will be of high-quality standard.
FDA
Food and Drugs Administration is USA based agency with primary goal to provide safe and healthy drugs and associated equipment. Therefore, a rotary tablet machine which is used for making drugs must meet with the FDA's rules.
CE
CE is the collective marking of European Union made to allow the mobilization of only those products which are conforming the Union's health, safety, and environmental protection standards. Hence, presence of this mark on a rotary tablet machine will strengthen its quality.
Rotary tablet machine can be integrated with other machines to facilitate larger production output. The list of these machines has been provided below:
Tablet Deduster Machine
Allpack Top rotation type tablet deduster machine SZS230
Tablet deduster machine is one of the essential equipment that can be attached to a rotary tablet machine. It is used to remove out the dust and residues from tablets after their pressing. It consists of a main frame, chassis, vacuum device, dust collection plate, infeed, and outlet etc. It works by following the principle of vibration.
The mechanical force generate vibration which results in tablets scattering and moving over perforated plate. At this point, the dust is collected through vacuum device and tablets are free from dust.
Tablet Coating Machine
Allpack tablet coating machine BYA-600
Tablet coating machine is another equipment that can be integrated with rotary tablet machine. It is employed for coating the tablets with thin coating film. Several components constitute its body including a coating pot, heating device, control panel, and machine base etc. It coats the tablets by continuously rotating them in a coating chamber where fluidized coating formula is sprayed over the tablets resulting in even coating.
Tablet Counting Machine
Allpack APC-8 Automatic Tablet Counting Machine
Tablet counting machine is the most important machine which go side by side with rotary tablet machine. It has been designed with automatic technology to count the tablets through sensors and vibratory trays and then fill these counted tablets into various bottles and containers. It is made up of several parts comprising a hopper, vibratory channel, counting compartment, filling head, and automatic detection system.
Blister Packaging Machine
Allpack DPP-180H High Speed Tablet/Pill/Capsule Alu Alu Blister Packaging Machine
It is a primary packaging machine mostly used for tablets packaging. This blister packaging machine is used to create blister packs in round or oblong shape to hold tablets and pills. The machine uses, film roll, thin aluminum foil, heating system, and detection system to precisely form the blister packs, accurately place the tablets in blister packs, and seal them through aluminum foil.
Regularly maintaining your rotary tablet machine can enhance the working life of the machine and also keep its pace at good condition. In this way, below discussed are some of the notable tips whose following will help you achieve the maintenance of a rotary tablet machine:
Lubricating mechanical parts of machine- Picture Courtesy: geartechnology.com
Dusting & Cleaning:No doubt, cleaning is the obligatory part of maintaining a rotary tablet machine. So, you need to dedust the parts of machine after the machine complete one round and wash these parts when daily task gets done. These parts include the hopper, fill parts, compression rollers, dies and punches. Parts like control panel, handle, and control board can be wiped out with cloth.
Lubrication:Lubrication is another important step in maintenance of a rotary tablet machine. Here, you need to lubricate the transmission parts of machine-like rollers to improve their motion fluency.
Parts Changeover:After cleaning and lubrication, it is significant to have a look towards the damaged parts of machine. If you find components in unsuitable condition, then make sure to timely change them with new spare parts.
When operating a rotary tablet machine, it might show malfunctions that can lead to bigger challenges like tablets breaking and capping etc. These pitfalls are caused due to technical issues that occur inside the machine. To troubleshoot these errors timely you need to have relevant knowledge about it which is given in the table below:
No Pitfalls Causes Solutions Pictures 1 Tablets capping happening after compression The reasons are trapped air inside die cavity and the excessive dry nature of powder. It can be tackled by increasing the dwell time of pre-compression stage, so, the air will get more time to come out. Also, make sure the powder has enough lubrication to make it compact.Capping of tablets- Picture Courtesy: romaco.com
2 Lamination of tablets Over compression is the core reason for lamination of tablets where they get cracked. Another reason can be the use of inappropriate dies. So, you need to enhance the pre-pre-compression time to lead powders stick together and use tapered dies which are best for avoiding tablets lamination.Laminated tablets- Picture Courtesy: sciencedirect.com
3 Tablets particles stick to the punch tips or heads It is one of the serious issues that occurs as a result of particles being wet from inside leading them to stick to punch head. In some cases, the punching tools are also responsible for particles picking. The solution lies in properly drying the powder mixture after its wet granulation tool place. Moreover, increasing the dwell time of pre-compression roller will give time to powders for drying. Along with that, daily polishing of punching tools will highly reduce the chances of tablets sticking to their heads.Tablets sticking to punches heads- Picture Courtesy: researchgate.net
4 Tablets binding happen inside the die restricting way for tablets ejection Too much binding agent causes tablets' sides to take hold in die cavity which can make them crumble when ejected. Reduce the lubrication or binding agent in tablets and make sure the mixture is well dried.Tablets with rough sides- Picture Courtesy: asme.org
5 Tablets friability Tablets’ friability leads to challenges in their coating, packaging and delivery. It has various reasons encompassing the low number of binders, excessive compression speed, and large granules with no fine powder. Solution is simple, you need to add sufficient binders into mixture, reduce the compression force of machine to suitable level, and reduce the size of granules.Broken tablet- Picture Courtesy: eastmedpharmacy.co.nz
Purchasing a rotary tablet machine means including in your production line a determiner who will determine critical things about your business such as the manufacturing output, size and shapes of tablets, and cost of production. So, make sure you are choosing this machine attentively!
Production Capacity
Capacity puzzle- Picture Courtesy: adults.ccinform.co.uk
The first and most critical factor to look for is the production capacity which you are planning to have. Since, there rotary tablet machine is available both in automatic, semi-automatic, single sided and double sided form, you can opt according to your needs.
Shape & Size of Tablets
Different sizes & shapes of tablets- Picture Courtesy: shutterstock.com
Another crucial consideration comes on part of the tablets' shape and size. Here, you have to pick for right assembly of punches and dies whose specifications are compatible to your desired ones.
Type of Feeding System
Rotary tablet machines come with two types of feeding system: open feeder and closed feeder. Open feeder has poor flow ratio, which is good for granulated mixture compression, while as, closed feeder has fluent feeding frequency and is suitable for powders. So, make sure you opt for the rotary tablet machine with an intended feeding system.
Allpack is providing a suitable collection of rotary tablet machines. Have a look towards it!
No Machine Production Capacity Per Minute Number of Dies 1 Allpack rotary tablet press machine ZP-5B tablets 5 2 Allpack Rotary tablet press machine ZP-7B tablets 7 3 Allpack Rotary tablet press machine ZP-9B tablets 9 Allpack Rotary tablet press machine ZP-7B tablets 11We are wrapping up this buying guide about a Rotary Tablet Machine with great enthusiasm and a hope that you have found this piece of writing a helpful one. Rotary tablet machine is the answer to all problems that are being faced by today's manufacturers in medical field, food sector, and pesticide industry. It is the most updated version of tableting machinery as proved by the above discussed vast classification of a rotary tablet machine. So, now it's your turn to revolutionize your tablet making business. If you are eager to learn more, stay in contact with us!