COMPRESSION

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  1. 1. TABLET COMPRESSION MACHINE 1 Department of Pharmacy (Pharmaceutics)Department of Pharmacy (Pharmaceutics) || Sagar savaleSagar savale Mr. Sagar Kishor SavaleMr. Sagar Kishor Savale Department of Pharmaceutics avengersagar16@gmail.com 2015-016
  2. 2. CONTENTS • Introduction • Process of tablet compression Compression and consolidation Decompression Ejection Scrape off • Rotary tablet press design • Mechanism rotary tablet machine • Press design and layout • Troubleshooting • Reference’s 2
  3. 3. Introduction • The most common method of drug delivery is oral dosage form of which tablet and capsule are predominant. • Tablet is more accepted as compared to capsule due to many reason such as cost, tamper resistance, ease of handling, ease of identification and manufacturing efficiency. • Tablet compression process understanding is resulted in development of formulation. • Recent advances in the design of tablet compression equipment has conducted resulted in higher efficiency, minimized tablet variation, greater flexibility. 3
  4. 4. • Modern machine provides greater accuracy and efficiency as follows:- 1.Improved material feed system. 2.Improved cam design and material of construction. 3.Multistage compression. 4.Isolated design for quick cleaning and changeover. 5.Improved force measurement techniques. 6.High speed single tablet sorting to reject out of specification tablets. 4
  5. 5. Rotary Single Tooling “D” “B” “BB” No. of station 10 16 20 Max. output (tab/hr) 18,000 28800 36000 Max.pressure (ton) 6 6 6 Max.tablet die 16mm 13mm 11mm Length of punch 133.65mm 133.65 mm 133.65 mm Max.depth of fill 17mm 17.5mm 17.5 mm Electrical motor 1.5H.P.,1 Phase,1140rpm Net weight 310 kg Gross weight 400kg Over all dimension 600/700/1020mm 5 MINI PRESS-I
  6. 6. PROCESS OF TABLET FORMATION • The quality of compressed tablet is determined by material fill characteristics and compression behavior. • Die fill characteristic depend upon material flow properties . • Steps involved in tablet formation:- 1.Compession and consolidation 2.Decompression 3.Ejection 4.Scrape-off 6
  7. 7. 1.COMPRESSION AND CONSOLIDATION • During compression the bulk volume of material is reduces resulted in the displacement of air. • Increase in force lead to particle deformation and rearrangement at this stage three principle mode of deformation are follows:- 1.Elastic deformation 2.Plastic deformation 3.Brittle fractures 7
  8. 8. CONSOLIDATION:- • Consolidation means bonding. • The final tablet properties are affected by consolidation (i.e. bonding). • Mechanism of consolidation:- 1.Mechanical theory. 2.Intermolecular forces theory. 3.Liquid-surface film theory. 8
  9. 9. DECOMPRESSION • The rate at which force is removed (dependent on the compression roller diameter and machine speed). • The rate of decompression can also effect on the ability of the compact to consolidate (form bonding). • Based on liquid-surface film theory the rate of crystallization or solidification and should have effect on the strength of bounded surface. • High decompression rate should result in high rate of crystallization, typically slower crystallization rate result in stronger crystals. 9
  10. 10. EJECTION AND SCRAPE-OFF • Tablet ejection-the initial ejection peak force required to break the tablet adhesion to die wall. • Inadequate lubrication resulted in high ejection force and possibly tablet failure and there is chances of striation along with the tablet side wall and picking, sticking. • Ejection force below 200N-optimal upto 400N-common high 400-800 high 10
  11. 11. ROTARY TABLET PRESS DESIGN • Pharmaceutical tablet was generally produced on rotary tablet press. • Upper and lower punches reside in upper and lower turret. • Dies are inserted in die table and the dies are secured by die lock screw. • The upper and lower turrets and die table are precisely aligned. • The movement of punches is controlled by cam track and compression roller. • As the entire assembly rotates the upper and lower punches move along the cam track to accomplish die fill tablet, compression, ejection and scrape-off . 11
  12. 12. PRESS DESIGN AND LAYOUT • Modern rotary tablet presses are typically designed in separate machine section. • Rotary tablet compression machine having following section. 1.Upper cam section 2.Lower cam section 3.Compression section 4.Lower mechanical section 12
  13. 13. UPPER CAM SECTION • It consist of all upper compression roller and all adjustment to the position to the upper compression rollers. • The primary component of upper cam section are as follows, 1.Upper punch removal/dwell cam. 2.Upper punch lowering cam. 3.Upper precompression and main compression rollers insertion depth adjustment . 4.Upper punch pull up-cam. 5.Cam material of construction. 13
  14. 14. COMPRESSION SECTION • The compression section contain all components that are exposed to the material. • The compression section following part 1.Material hopper 2.Feed frame 3.Excess-material stripper 4.Tablet stripper 5.Material recirculation 14
  15. 15. LOWER CAM SECTION • The lower cam section is completely sealed from the compression section . • It houses the lower compression rollers, the entire lower cam track that guided the lower punches as the turret rotates. • The following part included in lower cam section 1.Fill cam 2.Weight regulation cam 3.Precompression and compression rail 4.Ejection rail 15
  16. 16. LOWER MECHANILCAL SECTION • The lower mechanical section houses the main drive motor the gearbox, the hydraulic pump, the lubrication pump and signal wire distribution. • Proper venting and cooling of the lower mechanical section is essential to prevent machine damage and minimizing heat generation • This section should be equipped with cooling system for product that are sensitive to heat generation (e.g. contain low melting point component that are prone to picking and sticking 16
  17. 17. TROBLESHOOTING • A proper understanding of material compression characteristic combined with a knowledge of tablet compression equipment allows efficient troubleshooting of production problem. • Various tablet problem occur in processing 1.Tablet weight variation . 2.Low hardness. 3.Capping and lamination. 4.picking and sticking. 5.Tablet jam and chipping. 6.Poor flow . 7.Punch variation. 8.Hardness variation. 17
  18. 18. • TABLET WEIGHT VARIATION- It caused by various factor e.g. poor flow characteristics of granules, increasing machine speed. • If weight variation is excessive, the following machine component should be examined- 1.Condition of the lower punch pull-down cam . 2.Condition and position of excess material striper. 3. Feeder paddle speed can examined. 4.Minimum amount of material recirculation is necessary. 18
  19. 19. • LOW HARDNESS:- low hardness due to capping or noncompressibility. • Following guideline should be examined, 1.precompression and compression with large diameter roller. 2.press speed is reduced in order to increase total compression time . 19
  20. 20. • PICKING AND STICKING:- To minimize these problem the following areas should be examined: 1.Heat of compression 2.Press speed . 3.Precompression force 4.Tool condition 5.Tablet stripper 20

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