Multitip tooling has transformed the way tablets are produced and it is now seen as the most productive form of tablet manufacture. The simple process of adding multitips to existing machines can have a huge impact on production through increased output and reduced production time, without the expense of investing in new machinery.
Multitip tooling – the advantages
• Increased productivity – the number of tablets per turret rotation is multiplied by the number of tips,
• No large capital outlay on new tablet presses means that higher tooling costs are easily outweighed by increased output,
• Reduction in press run-time per output of tablets means that less maintenance is required per batch of tablets produced,
• Reduction in press setup-time per output of tablets,
Less tablet presses required to satisfy output, therefore requiring less floor space leading to more products processed per square metre,
• All of the above leads to reduction in overall plant running costs.
To minimise losses in the production of tablets, advancing and automating methods for measuring pharmaceutical compression tooling is crucial.
Despite the technological development in the field of process optimisation in the pharmaceutical industry, the use of measurement practices to assess the wear of punches and dies is not yet widely used. Observations show that in some companies producing drugs and supplements, the evaluation of the wear of the compression tools is still based only on the optical examination of the working part of the tools – or, worse, no measurements are carried out, which may lead to increased discards or major failures.
Punches and dies are one of the most important, and at the same time the most delicate, tools used in the production of tablets that work in an environment that always causes natural wear of these. The measurements ensure the preservation of geometric, weight and information parameters (embossing/ score line) of the manufactured preparations, and thanks to them, it is possible to diagnose:
- Natural wear of the punch,
- Damage to the working part,
- Damage to the shaft and head of the punch,
- Damage to the die hole resulting from natural wear (ringing) and mechanical damage
- Quality of embossing/score line
Manual measurement carries the risk of errors
In most companies, the measurements are carried out manually using contact sensors, requiring the operator’s professional knowledge in the field of metrology, experience in the industry and simply a good focus on the activities performed. The manual measurement method can also introduce a series of errors both due to the measurement tools themselves and the transposition of the measured data to the measurement reports. The total time to perform the expected measurements with the use of several points and measurement positions for one tool is also significantly extended.
Fortunately, more and more often the validation departments in the pharmaceutical industry impose the necessity of measuring the tools already at the production stage. Both in terms of measurement methods as well as tolerances and quality of measurements, these requirements become more and more stringent. There is also often question of the measurement methodology applied so far. The latest technological developments in the field of optical metrology have made it possible to introduce improvements in measuring tools and move away from outdated methods. Currently, measuring machines are equipped with high-quality sensors, ensuring high accuracy and measurement speed.
Knowledge in the field of measurement requirements and the latest achievements in the field of measuring technology has enabled Adamus to provide high-quality measuring machines for punches and dies on the market. The device for dimensioning uses full automation of processes in the scope of not only measuring but also at the level of tool delivery to the measuring chamber using the robot’s arm.
Measuring machines, based on the obtained measurement results, perform the pairing of punches. Automatic pairing algorithm allows users to minimise production losses due to the weight loss of tablets. The latest solutions enable the pairing of repeatedly popular multi-tip punches in the industry.
On the market, there are models of machines equipped with a camera and image analysis algorithms, thanks to which it is also possible to measure the embossing on the punch bowl. Measurements of that are made with an accuracy of up to 1μm, thus eliminating the risk of defective batches of products.
Furthermore, some measuring solution delivers database directly connected to the measuring system. That database, filled with historical and current measurement results, allows analysis of consumption trends. This makes it possible to order tools for maintaining production continuity before they are used up.
In the current production reality and with the high expectations of the consumer market, it is necessary to provide solutions that meet those expectations and even anticipate them. Automation of the measurement proces while maintaining a professional, strictly dedicated to the pharmacy approach, provides not only what the final product recipient expects – tablets – but also minimises losses during production, including emergency technological breaks caused by tools whose quality was not monitored.
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- Adamus continues to operate and support the customers.
- Adamus expands online product catalogue
- Adamus Coating - PVD CrN Coating
- Spare parts from top quality materials
Poster: Maximum tablet dimensions recommended by machine manufactures
In Adamus, we made everything to support our customers on every stage of tablet production. That's why we decided to create an online catalogue of our products. Now everyone can easily check our offer and in just a few steps send an inquiry to our sales department. With this solution, we are able to accelerate our customers' offer and customers have the possibilities to see our offers.
We extend our offer of the ultrasonic cleaner from 3 to 12 different-sized ultrasonic cleaners. On our website, you'll find 12 ultrasonic cleaners and 70 accessories.
We offer not only a wide range of punches and dies for tablet presses, We also have products and services that are helpful at every stage of tablet production:
We offer not only a wide range of punches and dies for tablet presses but also the products necessary during tablet production
- Spare parts for tablet press and capsule-filling
- Format parts for blister lines and carton machines
- Ti-2 automatic measuring machine for punches and dies
- Polishing machines for punches and dies
- Ultrasonic cleaners for precise cleaning of punches and dies
- Storage solutions for punches and dies
- Single-unit tablet presses to satisfy smaller production needs
And complementary services, including:
- Tablet design
- Tablet press service
- Tablet press Rebuilding and refurbishing,
- Rotor repairs
- Compression Tooling Academy
In the next few weeks, we will be developing our online offer.
You can be assured of our commitment to continue to support your business in the face of the changing conditions. In this regard, we would like to inform you that our AdamusTeam will be supporting all our customers. If you have any questions or concerns regarding the status of your order or upcoming service needs, please contact your usual sales or service representative.
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