High Speed Double Rotary Tablet Press Machine
MACHINE APPLICATION
AMPLUS - III High Speed Double Rotary Tablet Press is aptly designed for use in pharmaceutical Industry for Large Batch size Production for Single Layer as well as Bi-Layer Tablets. It does find its applications in many other similar process industries.
MACHINE OPERATIONAL PRINCIPLE
The material (Blended Powder/ Granules) is to be filled to the die hole through the hopper and the Feeder. Then, the filling volume of the powder is adjusted by motorized Dozer & pressed under the Pre & Main Pressure Rolls. The tablets are formed under this process & discharged automatically through the discharge chute of the Tablet Press.
MACHINE DESCRIPTION
This is a Double Rotary Tablet Press with inbuilt 10 Ton Pre Compression & 10 Ton main Compression, with Key features of Interchangeable Turret facility among 51 STN D / 65 STN B/ 81 STN BB. This ergonomically designed machine is cGMP Compliant Tablet Press meeting all the parameters of Design (smooth corners & surfaces), Operator’s safety, Control systems, Metallurgy, Surface treatment and Easy accessibility for cleaning, assembling and dismantling of components etc.
AMPLUS - III series Rotary Tablet Presses are controlled by 15” IPC WITH COLOUR TOUCH SCREEN WITH 21 CFR PART 11 COMPLIANCE. IPC supports online helps to provide the Automation solutions through internet & hence minimize the Machine Down Time and production loss.
This series of machines are designed and made as per cGMP STANDARD & are capable to meet all international standards including USFDA & MHRA REQUIREMENTS.
A) STRUCTURE
As the name suggests, the robust Structure design provides strength & stability to compression forces without vibration. Its sturdy construction based on 'TIE BEAM' design wherein the top frame, made of special C.I., supports the main body to withstand the pressure load during the entire tableting process. The trembling is also absorbed during the operation based on this structure. The structure is enclosed with SS 304 guards. The Tablet compression zone is covered with thick transparent acrylic guards. The machine is equipped with Anti Vibration mounts at the bottom.
B) TURRET DRIVE
Centrally driven Turret is connected directly on the Main Drive Shaft of Heavy Duty Oil Immersed Gear Box to get the max torque at the Turret. It is designed to meet the standards of Low Noise Level below 80db. Large capacity motor ensures that there are no jerks or slippages while compressing even large tablets of size up to 25mm.
C) TURRET
Highly accurately machined, 3 piece Turret with double tapper roller bearings, has SS 316 Die Table.
Upper & lower Punch Disk is made of Special Grade SGI Casting with Electroless Nickel Plating on the exposed portion in tableting zone. This Electroless Nickel plating provides excellent protection against corrosion from highly abrasive substances, salts, acids, alkali, humidity etc.
In upper Punch Disk, the keyway is given in upper punch bore for shaped punches. The Lower Disk is having the punch brake (Ball Plunger) which holds the lower punch, to reduce the weight variation & the Noise.
The lower wiper seal is fitted on the top part of the punch hole in order to block the Oil & dust from the Punch body.
Dies inserted in Die Holes are locked by specially designed & hardened Die Lock Assemblies.
The interchangeable Turret can be provided with option of ‘51D’, ‘65B’ or ‘81BB’ Tooling.
D) PRE & MAIN COMPRESSION PRESSURE ROLLS ASSEMBLIES
Equal & High pressure of Pre & Main Compression rolls, improves the dwell time for better compression. It eliminates the problem of tablet capping and chipping even for difficult formulations or shaped tablets.
Pre & Main Compression Rolls are specially designed, to deliver uniform Pressure on both the Upper & Lower Punches.
The motorized Lower pressure Roll Assembly has Load Cell, fitted at Center the lower roll, which enables the compressing Force measurement & monitoring. (Numeric as well as Graphical)
E) FILLING CAMS
3 types of the filling Cams are supplied along with the machine. A suitable one should be selected based on the Tablet Thickness. The maximum size of the Filling Cam is 20 mm.
F) FORCE FEEDER MECHANISM
Zero Clearance Force Feeder has User friendly design of the force feeder feeds the granules to the Die cavity uniformly. The Force Feeder has Single stage 3 Paddle design for optimum powder filling. Separate ACVFD Drive for Force Feeder is provided for uniform filling efficiency & weight control as well as to synchronize speed & feed both. Option of Clockwise & Anti Clockwise rotation of paddles can be selected from Touch Screen of IPC. It enables handling of difficult products with characteristics like low B.D., fluffiness, poor flow ability etc.
G) FEATURES & ADVANTAGES OF AUTOMATION
• All machine controls through IPC touch screen.
• Auto sampling based on, either time or revolution or punch nos.
• Initial startup & stop rejection by default
• Auto rejection, of any single tablet, if out of prescribed compaction force limit based on CFC through AWC facility.
• Graphical representation of pressure on individual punches at pre & main compression rolls.
• 4 level password securities to prevent unauthorized use.
• Recipe management & recipe storage.
• Audit trail reports with printing facility.
• Post installation. PLC complaints can be handled by internet through team viewer
H) AWC
• The range of AWC is divided such as control, reject and data store.
• Graphical representation of the value of both pre & main pressure.
• Display of figurer and graph both for the value of pressure on each individual punch.
• Indication / display, of any no. of the selected punch & the respective value of pressure applied on it.
• Filling depth can be adjusted, if the amount of filled powder is exceeded or shortened beyond preset value.
• The faulty tablet will be rejected automatically through Single tablet rejection system.
• All data like production, rejection samples taken. Batch time segments etc. are recorded.
• Discharge chute with three compartments viz. Acceptable tablets, initial / auto reject & sampling tablets gate.
I) CENTRALIZED SCADA MONITORING SYSTEM
Machine input & output status can be observed & monitored, in parallel to the machine connected panel, from outside, by any competent authorized person, while sitting in his office through any internet connected device.
BENEFITS OF SCADA:
• Report generation in PDF.
• Large no of recipe & data storage capability of IPC
• Connectivity to any type of printer.
• Graphical system representation.
• Real time trending
• Alarm history.
• Audit trail.
• Advanced security level.