For many manufacturers, to boost the output with equivalent investment or even less is a common pursuit in any industries, and the pharmaceuticals industry is not an exception. The pharmaceutical factories generally increase tablet production by 2 ways.
First is upgrading the machines and equipment. As we all know, rotary tablet press equipped with several stations of tooling produces thousand times of tablets more than the single punch tablet press which is only with one punch mold on. The same is true with the high speed rotary tablet press, which outfitted with hundreds of tab tooling on creates much more tablets than the medium speed rotary tablet press. Most of all, the high-grade machines are always designed and manufactured with advanced techniques, providing a strict system to guarantee the tablet quality, hardness, thickness, weight, etc. And, certainly, it will be a large investment. So the pharma should estimate their purchase capability and actual tablet output requirement. Always keep in mind that the suitable one is the best one. Make every penny exert its function.
Second is upgrading the tablet tooling. More than 150 years ago, multi-tip tooling came into our eyes. With several tips on one punch cup, it could make several tablets at one punching, which increases the tablet production in a direct way. Muti-tip tooling is available in two common configurations: mono-block (solid) type and assembly(or multi-piece). In the procurement process, consider the tool type, tablet size, and the number of tips per punch, and also consider tool handling applications, cleaning, maintenance, and inspection. Before that, maybe have a good understanding of the strength and weakness of each type is critical. Fette tooling and Ronchi tooling make a good job on this perspective.
• Mono-block multi-tip tools
This configuration is machined from a single piece, which is becoming popular as it requires no assmebly and disassembly for cleaning, inspecting and maintaining, saving time and labor force as well as avoiding abrasion in assembly&disassembly procedure. And most of all, the alignment of punch tips in the die get guaranteed.
However, machined from a single metal requires high techniques. And we should also take the pressure-bearing capacity into consideration. Too much press applied on one punch will damage the punch tips more or less. Given all these considerations, the mono-block type tool is always equipped with fewer tips in relation to tablet size. What’s more, this configuration is costly as we have to discard it as one tip or any damages occur. There’s no replacement to renovate it.
• Assembly multi-tip tools
The biggest advantage of the assembly configuration is the removable punch tips. If one of the punch tip on the mono-block tool is damaged, the entire tool must be replaced.
The cleaning and maintaining job of this configuration requires disassembling the punch tips from the punch body, and then cleaning and drying each component, then reassembly. Although reassembly should be quick and easy, if any of the mating parts become damaged or even nicked, or if a slight amount of debris or corrosion interferes, the punch tips won’t align. If we return the unaligned tools on the machine, it may fail prematurely or damaged the press.
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