COMPRESSION MACHINE
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CONCEPTS
Definition
Types Of Compression Machine
Parts Of Compression Machine
Basic Principle Of Compression
Working Principle Of Compression Machine
Critical Parameters
Sensors & Safety Features Of Compression Machine
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DEFINITIONS
Tablets are made by compressing a formulation containing a
drug or drugs with excipients on stamping machines called
Compression Machine.
There are several categories of tablet
• Uncoated tablets
• Coated tablets
• Effervescent tablets
• Dispersible tablets
• Soluble tablets
• Oro dispersible tablets
• Gastro resistant tablets
• Modified tablets
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Types Of Compression Machine
Single Punch Tablet Press
Multi Station Rotary Tablet Press
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Single Punch Tablet Press
It is called a single-punch tablet press as it makes one tablet at a time.
In single punch machines, all of the compression is applied by the upper punch
Multi Station Rotary Tablet Press
steps involved are:
Over fill Corrected Fill Compression Ejection
Termed As rotary because the head of the machine (Turret) that
holds the upper punches, dies and lower punches rotates.
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Parts OF Compression Machine
1. Hopper
for holding and feeding granulation
2. Dies
define the size and shape of the tablet
3. A feeding Mechanism
moving granulation from hopper into the dies
4. Punches
for compressing the granulation within the dies.
5. Cam tracks
for guiding the movement of the punches.
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Basic Principle Of Compression
Filling of the Dies
Dosing Of Dies
Compression of the Tablets
Ejection and Exit of the Tablets
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Filling Of Die
The material to be pressed reaches the feeder from the Hopper.
The fill cam below the feeder pulls the lower punches down by a fixed amount and the dies are
filled with material.
The quantity of the material filled is larger than the actual amount required
i.e. excess dosing is done.
Dosing Of Die
The dosing unit lifts the lower punches until only the desired quantity of material remains in the
dies. The excess material is transported back into the feeder.
Compression
After that, the upper cam course lowers the upper punch until the upper punches are inserted into
the dies. The lower punches are guide to the pre-compression roller. When the punches pass the
pre-compression roller, they are inserted a little more into the dies and the material is pre-
compressed and the slugs are formed. Thereafter, in the main compression roller, the tablets
reach their final height and hardness
Ejection & Exit
After the compression, the upper cam course pulls the upper punches into their top position
and simultaneously the ejection device lifts the lower punches until the tablets are ejected from
the dies. The tablet stripping device strips the tablets off the lower punches and passes them
on to the discharge chute.
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The stages in the compression cycle are shown in figure.
• Stages 1 and 2 in demonstrate filling and dosing of the dies.
• Stage 3 demonstrates the compression of the tablets.
• Stage 4 demonstrates the ejection and exit of the tablets.
• Stage 5 demonstrates the start of next cycle.
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COMPRESSION TECHNIQUE
Following Defect /trouble shooting Found During tablet compression
TROUBLE POSSIBLE CAUSE ACTION
Inconsistent weight 1. Variation in punch length 1. Replace the punch with correct one
2. Improve granules / mixing technique
2. Inconsistent granule 3. Check hopper /adjust the flow of
powder.
3. Empty force feeder 4. Replace
4. Brake plugs worn out 5. Reduced the speed of machine.
6. Adjust the material flow.
5. Dies not filled
Double impression 1. Worn out brake plugs 1. Replace
2. Excessive pre pressure 2. Decrease pre pressure.
Variation in thickness / hardness 1. Weight variation 1. Same as above
2. Worn pressure roll 2. Replace
3. Variation in punch length 3. Replace
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COMPRESSION TECHNIQUE
TROUBLE POSSIBLE CAUSE ACTION
Tablet breaking on take 1. Take of plate incorrectly set. 1. Check and reset
off 2. Lower punch ejection height incorrect. 2. Check and reset
3. Speed of machine to high.
3. Reduced speed of machine to get the
4. Granules to dry correct tablets
4. Increase the moisture level
5. Soft tablets
6. Scraper not set proper as per shape of 5. Check and set the hardness
tablets 6. Check and reset the scraper
Excessive material loss 1. Incorrect set of the feed frame 1. Check and reset
2. Upper punch penetration set to high 2. Check and reset
3. Inadequate dust extraction point 3. Reset
4. Excessive clearance between lower punch 4. Replace
tip to die bore
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TROUBLE POSSIBLE CAUSE ACTION
Capping / laminating 1. Granules to dry 1. Increase moisture level high
2. Reduce the speed of machine
2. Machine speed to high 3. Reduce the hardness within
allowable limit
3. Excessive pressure ( high hardness) 4. Apply require pressure
4. Pressure not given . 5. Set the punch penetration and try to
5. Tablets compressed in die at lower compressed the tablets at upper side
of the die.
Black particle 1. Excessive Lubrication 1. Check an set the require time
interval
2. Friction of parts which generate the 2. Check and reset.
particle
3. Dust cap filled with granules 3. Clean the dust cap.
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COMPRESSION TECHNIQUE
Some tablets Defects
Black particle Broken tablets Sticking
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COMPRESSION TECHNIQUE
Some tablets Defects
Capping /laminating
Edges /chipping Rough surface
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Working Principle of Cadmach CTX IIA Compression Machine
Operated On SCADA
SCADA
Supervisory Control And Data Acquisition
SCADA is a system operating with coded signals over communication channels so as to
provide control of remote equipment
A tablet press can be instrumented with a strain gauge that senses and reacts to compression force
changes. (CFC)
Compression force fluctuation is the result of slight changes in tablet weights. As the tablet weights
increases the compression force increases and as tablet weights decrease the compression force decreases.
As blended powders are being compressed there is a consistent and measurable force rhythm that is
detected using a strain gauge. The strain gauge sends a signal to control the volumetric powder fill level
(weight adjustment cam), which controls tablet weights.
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Operation OF Machine
Machine should run in 5 mode
Auto Run
Manual Run
In this Mode Turret & Feeder Jog, Turret Jog, Feeder Jog, Lubrication Jog Should Be done.
Before Setting By this Mode Feeder should be fill.
Test Run
Setup Mode
In This Mode All Function Can Be Change
For Initial Setting of machine
Product Mode
In This Mode Some Function Can not be Change
After Batch Setting Machine Run run In this mode
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Parameters Of Machine
Turret Parameter
In Which Following Parameter included
Speed (12 to 70 RPM)
Machine Guard Mode (By pass or Auto)
Hour Meter Mode (On / OFF)
Mode Of Dummy Punch (By Pass or Auto)
Force Feeder Parameter
In Which Following Parameter included
Speed (10 to 50 RPM)
Synchronized Speed Mode (By pass or Auto)
Feeder Pre Run Time (0 to 99 Sec.)
Feeder Post Run Time (0 to 99 Sec)
Depth Of Die Fill Parameter
In Which Following Parameter included
Depth Of die Fill
Tablet Thickness Parameter
In Which Following Parameter included
Upper Punch Pre Pressure
Upper Punch Main Pressure
Tab. Cylindrical Height Pre Pressure
Tab. Cylindrical Height Main Pressure
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Compaction Force Parameter
In Which Following Parameter included
Main Compaction Force Avg.
Compaction Force Control Mode (On /OFF)
Ind. Main Compaction Force limit Max (5 KN More than max Value of compaction force)
Main Compaction Force SD Limit Max%
Force Control Limit low(Should Be 0.25 KN Less Than Min Compaction Force)
Force Control Limit Max (Should Be 025 KN More Than Max Compaction Force)
Ind. Rej. Force Limit low (Should Be 2 to 3 KN Less than Min Compaction Force)
Ind. Rej. Force Limit Max (Should BE 2 to 3 KN More Than Max Compaction Force)
Sampling & Rejection Parameter
In Which Following Parameter included
Initial Tablet Rejection ON Time (0 to 999 Sec)
Mode Of Sampling (Off, Selected Punch , No Of Tablets, All Tablets In Continuous Mode)
No Of Tablets For Sample
Interval Time For Tablet Sampling (0 to 7200 Sec)
Punch No For Tablet Sample 1 to 5
Permitted Rejected Tab / Revaluation (1 to 37)
Lubrication Parameter
In Which Following Parameter included
Lubrication ON Time (0 to 60 Sec)
Lubrication OFF Time (30 to 500 Min)
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Load Cell
Two Types
Compaction Force Load Cell
Ejection Force load cell
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Graphs
Two Types
Bar Graphs
Trends Graphs
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Safety Features
Emergency Button release
Turret Motor Healthy
Feeder Motor Healthy
Hydraulic Motor Healthy
Lubrication Motor Healthy
Main Hydraulic System Pressure Within Limit
Hydraulic oil Level
Lubrication Oil Level
Air Pressure Low
Machine Guard Open
Hand Wheel Guard Open
Door For Electrical Panel Box
Punch Entry Piece In Position
Batch Size Continuous
Batch No Entered
Powder level
Ind Main Compaction Force Within Limit
Ind tab. Ejection Force Within Limit
Tab. Counting Proxy
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