Avoid cracks between two die bores in your turret!

Over a period of time machines start to face wear and tear. However if proper care and precautions are taken then you will be able to extend the life of your machines.

We will look into various aspects in later blog posts. Here in this post let’s address the problem of cracks that develop between two die bores of turret. 

A crack between two die bores is a common problem. What needs to be given attention to is the fact that once the crack is developed there is no way to correct the problem as it will only increase on further use. Ultimately the entire turret has to be replaced.

The main causes of turret cracking between two die bores is over tightening of die locking screws. This can be taken care of by making your operator aware of why the cracks happen and how best you can avoid them.

The problem of cracks between two die bores can be completely avoided by:

·         Using a torque wrench to completely avoid over tightening

·         Using smaller size die locking screws for smaller dies.

·         Using a better grade of caste iron for the turrets. 

1997 – Small tablets large volume

In the year 1997, we introduced ‘A’ tooling. These toolings are much smaller in size having a body diameter of 12.7mm and can make up to 10mm tablets. The maximum permissible load of ‘A’ tooling is the same as ‘B’ tooling i.e. 6.5tons (65KN).

Since ‘A’ Tooling had smaller diameter we could accommodate more Punches and Dies into a single Turret. Hence we developed the 59 Station Press in the same year [1997].

One of the key advantage is that the 59 Station Press increases the volume of production. Though you can produce the tablets of the size 10mm and below with ‘B’ Punches, if ‘A’ Punches are considered then your production increases. This is because a regular Double Rotary Press can accommodate only 35 Stations of ‘B’ Tooling, whereas ‘A’ Tooling can go upto 59 Stations.

This also makes the 59 Station Tablet Press a very good alternative for Multi Tip tooling that run into higher expense and maintenance. 

Spring Plugs - An easy method to lock your lower Punches!

One of the reasons why weight variations occur in your tablets could be due to the lower punches not being held in place.

In order to avoid weight variations in your tablets it is essential to use anti turning device for your lower punches. This will also reduce the wear of your lower punches. If proper locking is taken care of then it can reduce the noise level of the press as well. Add to this, the double impression on embossed tablets can be completely avoided.

Using Spring Plug is a much better method to lock your punches instead of the nylon plugs.

The earlier method required 3 parts:

1) nylon plugs 

2) spring strip and 

3) screw. 

The nylon plugs wear out very fast and they have to be replaced frequently.  It is also important to monitor the length of plugs from time to time. During tooling change over you need to remove each plug and set it again which is time consuming.

To reduce all these time consuming hurdles the Spring Plug is a better option.

In the spring plug system you need to only tighten the plugs once and lock them with a grub screw. During changing the lower punch you just need to pull the punch and push it back in. This saves a considerable time in change over of toolings

The major advantages of Spring Plug over the nylon plug system are:. 

1. Decreases Tooling change overtime
2. Requires only one time setting
3. You can set the required pressure on the lower punches. 

How to reduce metal contamination and black particles in tablet production

Safe and hygienic conditions are very important during tablet production.  At each step of production care is to be taken so that the final output is not contaminated in any way. The most common problems are that of the metal contamination and the black particles found in the final produced tablets. This causes a lot of wastage of not only the produced material but time, money and energy. Gravity Feeders are made of metal. Due to incorrect setting of the metal feeder it may rub against the turret causing particles to mix with the product.  

This was one of the key reasons on why the feeder was looked at in detail and many options were thought of. This gave rise to the concept of designing a feeder that is Food Grade and acceptable in the pharmaceutical industry. Hence the Food Grade Polymer was used so that the risk of contamination is almost nil.

The Multi – Chamber Feeder is designed in such a way that it can be easily fitted in most of your existing tableting machines. It has auto adjusting scrapper blade so no manual intervention is required. Add to this it minimizes weight variations in big tablets because it has more number of chambers. While the metallic feeder could get deformed or bent due to mishandling this does not happen with the Polymer Feeder. The amazing part is that with all these features your production could increase by 50%.