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Efficiency Shared Containment Knowledge Capsules at Full Speed
Efficiency Shared Containment Knowledge Capsules at Full Speed
Efficiency Shared Containment Knowledge Capsules at Full Speed
NEXT?
FETTE COMPACTING MAGAZINE 2019
EFFICIENCY i
New i Series: dust-proof and digital ready
CONTENT
TECHNOLOGY stands for everything we SERVICE covers all the services related COMPETENCE is the overarching idea Imprint Picture credits
offer in production technology – from to machines, process equipment and behind all our process-related services. © Fette Compacting GmbH, 2019; all rights reserved. Rights to all copy, photos Title, p. 4, 6–9, 14, 16–18, 22–29, 31: © Fette Compacting GmbH
tablet presses and capsule filling machines installations such as spare parts supply, This includes training, product trials, and graphics are held by Fette Compacting GmbH. Responsible acc. to German p. 12–13: Standard Process
through process equipment to tableting plant modernization and technical field application and Performance Consulting press law: Volker Reinsch; Editor-in-Chief: Volker Reinsch; Editing and realization: p. 15: LeeGroup
tools and format parts. service department. as well as engineering. Script Corporate+Public Communication GmbH and Fette Compacting; p. 18: Studio Thomas Schmitz
Design: Braun Engels Gestaltung p. 20: Martin Schöler: studioline HH1 GmbH & Co. KG; Sven Hems: Studio Thomas Schmitz
p. 28: Studio Thomas Schmitz
Efficiency i 4/ 5
4/
1. Innovative: 2. Integrative:
from dust-proof to containment system-compatible up to IoT and MES
The increased use of new pharmaceuticals, If containment is also required, a suitable For several years the i Series has been Thanks to the possible system integration, the
including highly potent active pharmaceutical solution can be swiftly found using the distinguished by its cross-generation system new tablet presses fit perfectly into existing
ingredients (HPAPI) means that containment Containment Guard option. In this case, the compatibility. This is also the case for the production environments. In other words, old
has become a key issue in production. It is emphasis is on “suitable”, as containment machines in the new i Series. Practically all and new machines can work efficiently
already apparent that “dust-proof” will soon systems are often oversized so as not to products with contact to the system assem- next to one another. But the system concept
be the minimum standard for pharmaceutical endanger the project result. But the Contain- blies remain unchanged despite its innovati- extends even further into the future: the
machines. The new i Series already features a ment Guard gives users a reliable basis for ve design. „Not new, but better. This is the new i Series features technical connectivity for
consistent dust-proof design in its most basic evaluating their individual containment based basic formula behind the features of the next state-of-the-art production environments,
version. The new window flaps with double on precise exposure measurements (see generation,” says Gierds. “If relevant processes up to “Pharmaceutical production 4.0”. This
safety barrier systems also help ensure pages 16–21). change in certain cases, Fette Compacting includes process equipment integrated via
operator protection when using active sub- also has a solution: as part of our Lifetime plug-and-play and open interfaces for connec-
stances. The press room is designed to Efficiency concept, we offer service packages tions to the Internet of Things (IoT) as well
optimize cleaning, as around 50 percent of all specifically tailored to the i Series, which as for a manufacturing execution system (MES).
enclosure parts and components have been support users with revalidation.” The interfaces correspond to the standard
removed, thus reducing the surfaces to be for data exchange in industrial automation
cleaned by around 70 percent. The tablet (Open Platform Communications Unified Archi-
discharge is a completely new feature; it is tecture, OPCUA). “The i Series is now digital
suitable for all standard formats and is entirely ready”, concludes Gierds.
dust-proof. This improves the workplace
quality and operator protection while product
losses and cleaning effort are reduced to a
minimum.
FULL POWER
FOR NUTRACEUTICAL
ENCAPSULATION
» CONSUMERS HAVE
BECOME BETTER INFOR
MED IN RECENT YEARS.
THEY HAVE CONVERTED
TO WHOLE FOODS, TO
NATURAL, BIOLOGICALLY
CERTIFIED INGREDIENTS
Standard Process is a pioneer in the produc-
AND PRODUCTS. «
Ingredients from the company’s own organic has been looking for an efficient capsule-filling
tion of natural, whole food supplements. The Andrew Holtz, Maintenance Manager at farm technology since 2015. On the other hand,
US company is also a pioneer in the operation Standard Process Standard Process, a US manufacturer of whole Fette Compacting has been looking for a field
of a root-and-branch new capsule filling tech- food supplements, has been using nutritious trial partner for its first capsule filling machine.
nology: the FEC40 from Fette Compacting. ingredients since 1929. The company’s goal is Scott Anderson, Vice President Operations
Through a field trial that sets the benchmark. to provide foods that are as close as possi- at Standard Process, looks back at the begin-
ble to their natural form. That is why it grows ning: “One thing led to another, and we
The market for nutritional supplements is grow- more than 80 percent of the ingredients it joined forces to take the highest-performance
ing fast. Market researchers estimate global uses. Its 420 hectare organic farm in Wiscon- capsule filling machine in the industry, and
annual sales to be around 133 billion US dollars. sin harvests more than 2,500 tons of veg- to test it intensively under production condi-
They expect growth of 7.5 percent a year etables each year. tions. We wanted to find out whether the
until 2024. Vitamin-based supplements alone limitations of our existing capsule filling ma-
are expected to make up almost half of sales Holtz explains what happens after harvesting: chines could be overcome, including speed,
by the end of 2024. “We process our crops immediately so as to flexibility, uptime and the ability to process
minimize the loss of phytonutrients and retain demanding formulations.”
This trend goes hand-in-hand with a change the valuable nutrient complexes. Quality
in consumer awareness. “Consumers have control of the processing, such as checking The result, the FEC40 capsule filling machine,
become better informed in recent years. They for microorganisms and gluten content, takes lived up to its promise: With a yield of up to
have converted to whole foods, to natural, place continuously. Finally the ingredients 400,000 capsules per hour at 140 cycles per
biologically certified ingredients and products.” are precisely mixed and made into tablets or minute, the FEC40 has set new standards
So says Andrew Holtz, Maintenance Manager capsules. We offer about 50 different pre- for efficiency. Thanks to the high output, pro-
at Standard Process. “Customers nowadays parations in capsule format, either as gelatin duction costs for each 1,000 capsules
expect high quality ingredients, and look for or HPMC capsules.” have fallen by up to 30 percent. In order to
quality products and quality companies, reach this dimension of performance,
companies who demonstrate respect for their The FEC40 overcomes limitations Fette Compacting’s engineers have developed
employees and for the environment.” To do justice in the same way to the high the first double sided capsule filling machine.
quality requirements and the growing demand Fette Compacting has carried the general
for nutritional supplements, Standard Process technical concept of the FEC40 over to a sec-
ond machine for medium batch sizes: the
FEC20, the single sided version which has a
yield of 200,000 capsules.
The FEC40 at Standard Process 12/13
» BY THE END OF
THE YEAR, THE FEC40
HAD ALREADY TAKEN
25 different products on this machine. The batch
OVER NO LESS THAN size was the primary factor in the question
41 PERCENT OF of which products should run on this capsule
filler. In the light of the FEC40’s output, it
OUR TOTAL CAPSULE
made sense to process those of our products
PRODUCTION. « with the highest volumes on this machine at
Scott Anderson, Vice President full power – with great success.”
Operations at Standard Process
Standard Process was impressed with more
than just the machine itself. “Fette Compacting’s
services also include training for operators and
maintenance staff, the availability of telephone
support at any time from Fette Compacting
Servo and torque drives instead of the The TRI.EASY design of the FEC40 is tailored America in Rockaway, New Jersey, and
synchronized cam driven system for optimum operation. It allows for a 360° Fette Compacting in Germany, along with the
Anderson views the intelligent drive using approach, even when process equipment is online faultfinding through a direct, off-site
servo and torque motors as a central advan- connected, so that the stations can be login at the machine,” explains Anderson. “We
tage of the FEC technology: “The drive gives accessed easily. “The edge that the FEC40 particularly value their responsiveness. Very
us enormous flexibility when setting up and has over every other capsule filling machine, few vendors have partnered with Standard
refitting. All of our other capsule filling ma- apart from the output, is above all the ease Process to provide the fast responsive service
chines are controlled by cams, which makes with which the tamping pin stations can be ex- like Fette Compacting does.”
adjustment extremely time-consuming, or changed,” adds Anderson. “The operator
even impossible. With the FEC40 on the other can dismantle them and clean them outside
hand, every process step can be adjusted the machine. This saves us any number of
separately. To accelerate the set-up process, intermediate steps and adjustment work
the parameters are saved with the formulation before the machine is ready to operate again.”
for every product. This means that downtimes A human machine interface (HMI) with a
are shortened from what used to be several 19“ touchscreen and integrated keyboard al-
hours down to a few minutes. On top of this, lows for intuitive user guidance. It ensures
the operator can even make adjustments a total overview of the process and quality para-
during operation, for example to maximize meters at any time.
throughput.”
From zero to 41 percent of all capsules
For Standard Process the FEC40 is equipped
with twelve stations, 24 capsules each.
Anderson summarizes the final test phase:
“During the first half of 2018 we manufactu-
red a wide variety of products with a large
range of flow and compressibility properties,
in 0 and 00 capsule sizes. By the end of
the year, the FEC40 had already taken over
no less than 41 percent of our total capsule
production. We have manufactured
FEC20 at LeeGroup 14/ 15
EVERYTHING
UNDER CONTROL
» OUR WIDE RANGE OF
VARIOUS PRODUCTS
MEANS THAT WE HAVE
FREQUENT BATCH AND
PRODUCT CHANGES
The Swiss LeeGroup GmbH has opted for the LeeGroup
DURING CAPSULE PRO
FEC20 capsule filling machine offered by The Swiss LeeGroup GmbH has been developing
Fette Compacting. For its numerous capsule DUCTION. AS A RESULT, high-quality foodstuffs under the Lee-Sport brand name
products, this new company was on the since 2012 which the company offers online as powder,
SPEED IS A VERY
lookout for a machine which enables a high capsules, tablets, bars or in the form of dried fruit. Under
degree of process control and short con- IMPORTANT FACTOR. « the motto of “Shape, Health, Performance”, Lee-Sport
version times. Nathanael Lee, Division Manager Production products are oriented toward health- and figure-conscious
at LeeGroup customers, sports fans, and the elderly. The organic
“The main difference between the FEC20 and quality of products has been confirmed by a certificate
other capsule filling machines is the fact since 2015 and many preparations are also vegan. The
that it permits full control of the production startup has been extremely successful with this concept.
process,” claims Nathanael Lee, Division As its products are gaining in popularity, storage and
Manager Production at LeeGroup. His enthu- production have already been obliged to relocate on two
siasm at the technical excellence of this occasions due to a lack of space.
machine is clearly obvious.
In early 2019, Lee ordered an FEC20 from Rapid growth production. As a result, speed is a very impor- In an effort to accelerate conversion of the
Fette Compacting with the aim of commissio- The Swiss company currently sells 24 different tant factor,” explains Lee. “The special drive machine, the FEC20 features a patented
ning it as soon as the following fall. Under protein powders in more than 20 flavors via concept displayed by the FEC20 reduces the removal system for the tamping pin station.
the Lee-Sport brand name, LeeGroup develops, its web shop. These are supplemented by overall process time without any compromises And the filling stations can be easily disman
produces and sells a wide variety of special around 70 different preparations in capsule on quality. Furthermore, machine setup is tled and cleaned outside the machine. Where
foodstuffs and nutrition supplements. Whether and tablet form. “We introduce new products recipe-controlled which means that produc- additional pre-fitted filling stations are used,
organic cocoa, linseed oil capsules or baobab to our range every month. And the future tion can be recommenced without mechanical the FEC20 is ready for production within
fruit powder, the company’s online shop offers will see us continuing to extend our range and intervention.” an extremely short period of time. This enables
nutrition-conscious customers a range of maintain dynamic development,” adds Lee. manufacturers such as LeeGroup to swiftly
everyday to exotic products. This strategy has been a resounding success Continued cooperation change dosing methods, products and batches,
for the startup to date: since its establishment As for the larger FEC40, the FEC20 enables and immediately react to market demands.
in 2012, revenue has doubled each year. the process steps associated with capsule
filling to be controlled and monitored separately. Apart from the FEC20, LeeGroup does not yet
A decisive contribution to this rapid growth The assemblies in capsule filling machines have any other Fette Compacting machines
is made by the company’s capsule products. are usually controlled by mechanical coupling. in operation. But that could change very soon.
The range currently includes more than The FEC Series, however, uses individually “The technical advantages of the FEC20 Lee-Sport develops, produces and sells special foodstuffs
30 different preparations sold as capsules. controllable servo and torque motors for each and the very good support offered were deci- and nutrition supplements.
Some of them contain classic nutrition supple- process step. This enables users to individ sive factors for opting for collaboration with
ments such as calcium while others have ually specify the optimal parameters for each Fette Compacting,” claims Lee. “We hope
more unusual ingredients like turmeric or green- partial step of the filling process which to continue this cooperation within the frame-
lipped mussel. “Our wide range of various significantly improves the quality of capsules, work of other projects.”
products means that we have frequent batch output per time unit, and safety.
and product changes during capsule
Containment Guard 16/ 17
WHAT HAD
TO BE SHOWN
In Containment Guard, Fette Compacting has developed a measuring Avoid unnecessary costs
system that reliably predicts the retention performance of a contain- Being able to predict the containment performance of a plant before it
ment system. But does the laboratory data correspond accurately starts operating would be truly valuable to pharmaceutical manufac
to the values from real tablet production? A comparison with contain- turers: on the one hand the technology is expensive, and on the other
ment measurements taken at a large pharmaceutical concern has hand the containment level of a new plant must be specified at a
provided exciting results. very early stage. That is not easy, because until now predicting the con-
tainment performance was very difficult. Factors such as the ambient
"In the beginning they were rather sceptical," said Dr.-Ing. Martin surroundings or the operative play too big a part. Until now, it has
Schöler, Head of Engineering & Design at Fette Compacting. “Until only been through their own hazard measurements that manufacturers
now, pharmaceutical companies simply assumed that we machine have discovered how much retention performance their new plant
manufacturers could not reliably predict the performance of a contain- really offered. At that stage, however, the plant has already been
ment system. We’ve put an end to these concerns now.” installed.
Over the past few years, Schöler and Fette Compacting have devel- Every investment is a high financial risk for the project manager: if a
oped the Containment Guard, a seven-cycles measuring system decision is taken to use too much containment, unnecessary costs
that determines the retention performance of containment tableting sys- arise. If the calculation is stricter, but is based on an unreliable assess-
tems. Containment is a central topic for the pharmaceutical industry: ment of the containment, a plant with inadequate performance may
year after year, manufacturers have been processing larger quantities be the result. The machine must be laboriously upgraded if operatives
Containment Guard is a seven-cycles method that of highly active ingredients like those used in cancer and hormone are to be protected after all. Unnecessary costs arise again.
determines the retention performance of a containment therapies. Operative protection is ensured through ever-better contain-
system using reproducible measuring techniques. ment systems.
Containment Guard 18/ 19
Shared knowledge
Fette Compacting is at present also working together with other
famous customers from the pharmaceutical sector in order to put the
Containment Guard is the solution to this problem. It is with this In order to get clarity, Fette Compacting has been exchanging data for shared knowledge about good containment on a broad foundation.
system that Fette Compacting has developed a risk-based measuring some time with its customers, comparing their data records with Hems explained that, “In general we are seeing high levels of interest
method, in line with the criteria of the International Society for Fette Compacting own. The comparison with measurements taken at in exchanging data.” The main reason for this is that the manufactur-
Pharmaceutical Engineering (ISPE), which determines the retention globally active pharmaceutical companies was a great success. ers themselves also profit from it: “With external data, responsible pro-
performance of the plant by means of reproducible measuring tech- ject managers can check their own measurements. It is also reassu-
niques. In contrast to the standard measurements taken in the One company shared the data from measurements taken at ring for them to know that in future they can rely on the machine manu-
past, Containment Guard follows a seven-cycles protocol. The method the 2090i WiP tablet press, on which highly active ingredients have facturer’s measurements.”
also takes fault scenarios into account, as well as steps that have in been processed for some years, with Fette Compacting. Martin
the past been ignored. „It used to be said that measurement data from Schöler was really pleased by the comparison with the Containment In full sympathy with the idea that shared knowledge gives everyone
different plants couldn’t be compared. We have, however, enabled Guard values taken on the same machine constellation: “The data greater security, Fette Compacting will share its assembled con
this comparison through holding a large number of parameters con- from the pharmaceutical company matched our own measurements tainment know-how with the sector. To this end, the solid product
stant,“ explained Schöler. extraordinarily well,” he explained. The agreement between the specialists have prepared a manual that makes the way in which
measurements shows that Fette Compacting has a very good under- Containment Guard measurements operate available to the public. This
Practical test passed standing of the most important factors influencing containment – manual explains the details of the seven-cycle measuring technique,
To determine the containment performance, Fette Compacting much better than is usual in the marketplace. “You could say that and provides a professionally-based insight into the current state
assembles plants at the Competence Center in Schwarzenbek under Containment Guard passed the practical test with honors,” of knowledge surrounding the topic of containment. “For us, this is the
laboratory conditions. But how reliable, really, are the values that are added Schöler. first step to an entirely new understanding of containment, one that
measured there? “Until now we could not compare our laboratory will benefit the whole of the sector,” says Schöler. “Right now we are
values with measurement data from the real world. That meant that we laying the foundations that in future will earn us even more trust on
could not be certain whether pharmaceutical companies would come containment issues.”
to the same result in their own risk evaluation,” explained Sven Hems,
Manager Containment Systems at Fette Compacting.
Containment 20/ 21
KNOWLEDGE
CREATES SECURITY
Mr. Hems, Fette Compacting works closely with customers to match What benefits do customers reap if they work together with What is the outlook for Containment Guard going forward?
the Containment Guard measurements with the containment Fette Compacting on the containment topic?
performance in real, productive operation. What has been your Schöler: By developing a standardized measuring method we have
experience of that? Schöler: Every bit of new knowledge about containment improves significantly extended our understanding of good containment and the
working safety in the long term. And this knowledge grows with every underlying processes. We want to share this knowledge with the whole
Hems: Nothing but good so far. In the course of our cooperative work exchange of data. Being able to have one’s own measurements of the industry. That is why we have put together a guideline in our
with pharmaceutical companies, we have noticed a great readiness reflected as an external partner is very helpful. The principle of two manual about containment, where we have made our method – and
to exchange data on the containment topic. We have held a lot of pro- pairs of eyes reinforces the confidence in having measured correctly, the knowledge we have gained so far – transparent and freely
ductive discussions, and we expect further companies to share and that no surprises are lurking. The majority of companies are, for available. We see that is the first step to establishing Containment Guard
their measurement results with us. Everybody in the pharmaceutical this reason, very ready to share their data with us. as a standard for the whole sector, and to make our measuring
world is interested in know-how and in data exchange. For a long methods public in the service of user protection.
Sven Hems, Manager Containment Systems time now, pharmaceutical companies have exchanged data in other Hems: From granulation through to the final packaging, pharmaceutical
by Fette Compacting fields such as tableting, equipment, working processes, and companies have an overview of the entire process, but we have a
worker safety. Until recently, there simply hadn’t been very much about more detailed insight when it comes to the partial process of tableting.
containment that could be shared. We know all the possibilities and the risks for the containment of a
tablet press. That is the reason why we know exactly how we need to
Dr. Schöler, what knowledge has Fette Compacting gained as a measure an installation if we are going to achieve meaningful results.
result of the work on Containment Guard and the exchange of data
with pharmaceutical companies?
Learning with high scores and an avatar The test mode is another highlight, where Digital outlook: troubleshooting with a guide
The virtual training process requires the use of employees can complete a test in the virtual and augmented reality
Avatar “Helmut” is there to provide assistance if you a gaming notebook, VR goggles, and two world. Those who master certain tasks In addition to the VR training, Fette Compacting
A significant cost factor in pharmaceutical production get stuck in the virtual cleaning training. controllers. The employee slips into the virtual receive a certificate. is working on other digital applications
is incorrect operation, often caused by a lack of training glove ports and learns the cleaning process that are primarily intended to provide valuable
or well-intentioned but incorrect actions when trouble- based on an interactive checklist. The brain But employees are not just guided through assistance with troubleshooting. For exam-
shooting. Fette Compacting tackles these problems at perceives these actions as real. To increase the process by checklists and illuminated ple, this includes a digital step-by-step guide
their root – with the help of new digital tools. An initial the level of immersion even further, the devel- objects. “Helmut” is also there to help with that provides troubleshooting instructions
training program in virtual reality is already ready for use: opers even recorded the actual sounds for the initial training. The avatar is based on based on the error messages issued by the
the preparation of an isolator for cleaning with avatar every activity and integrated these into the pro- a real person called Helmut Bommrowitz, tablet press. In the event that even this
“Helmut”. gram. For instance, the operator hears Manager Technology Center and long-term instructed troubleshooting is not successful,
the typical clicking when they close the glove Fette Compacting employee. “In my so far in future, users will be able to count on
“A machine is only as good as the people operating it,” port in virtual reality. A high score provides 47 years at Fette Compacting I have answered real-time remote support with an augmented
stresses Britta von Selchow, Head of Digital Product additional learning motivation: the highest countless questions on the tablet presses,” reality function. In the next issues of
Innovation at Fette Compacting. Around half of all errors scores are obtained by employees who remove reminisces Bommrowitz with a grin. “So my What’s Next? we will report on this and other
in pharmaceutical production occur due to inadequately a particularly high number of product residues colleague Britta von Selchow asked me digital solutions from Fette Compacting.
trained personnel. The resulting costs for companies at critical points in the isolator. if I would like to be available virtually as an
reach up to the high six-figure range every year. Training avatar.”
sessions are therefore essential for efficient and reliable
production.
TARGETED TRAINING
Since 2017 Fette Compacting has been Not just for new employees Rather than having to work through a complete any one time. “Measurements confirm that the
offering training sessions that address the To support pharmaceutical manufacturers, training course in an area, the multiple-choice product quality and product loss were able
specific knowledge gaps of employees in Fette Compacting offers skill-based training test can be used to compile a customized to be returned to the original values after the
pharmaceutical production. A questionnaire courses, which identify and specifically program with the critical contents. This reduces skill-based training sessions. What’s more,
initially documents the current level of address these kinds of knowledge gaps that the length of the training and ensures that after the training sessions, the speed of pro-
knowledge in relevant areas of competence. are often passed down from employee to topics in which people already feel comfortable duction increased beyond the values recorded
The results are used to prepare tailored employee. A multiple-choice test initially deter- are not repeated. Another benefit is that before the new appointments,” reports
training programs for individuals or teams. mines the relevant knowledge in the areas employees do not need to spend an unneces- Klingenhof.
The case of a medium-sized pharmaceutical of mechanics, electronics, and operation. The sary amount of time out of the production
manufacturer shows: skill-based training result shows the knowledge gaps that exist area for the training.
enabled productivity to be increased in a for individual employees as well as whether
short space of time. the entire team lacks certain competences. Higher production speed after targeted
training sessions
A high-quality tablet press is distinguished The questions in the test vary in their degree The case of a medium-sized pharmaceutical
by its ability to make precise adjustments. of difficulty. Particularly easy and general manufacturer demonstrates the success of
This allows the optimum result to be achieved questions should be able to be answered by the skill-based training approach: the manu-
when manufacturing demanding pharma- all, while only a few people in a team need facturer recruited several individuals at the
ceutical products. Well-trained personnel are to be familiar with the difficult and specific con- same time, who had previously had little expe-
required to fully exploit this potential. “A tents. “What is inconvenient is if no one can rience in the pharmaceutical industry. This
Fette Compacting tablet press has over one answer a question. In this case, it is clear that quickly led to lower tablet quality, higher prod-
hundred production parameters. But what there is some catching up to do,” explains uct loss, and slower production.
good is that if only twenty of these are used Klingenhof.
effectively?” asks Tim Klingenhof, Head of To counter this, the manufacturer decided to
Training at Fette Compacting. The skill-based training is not just intended provide direct training for the entire workforce.
for new personnel. It can also be used as The results of the multiple-choice tests
Getting staff experienced in pharmaceutical supplementary training or as a refresher, where were used to pair up employees depending The multiple-choice test is the basis of
production to teach new employees has the it provides a good opportunity to increase on the knowledge gaps and language skills. the skill-based training sessions.
benefit that every new person receives individ- the overall efficiency of production, or to provide In total, Fette Compacting held seven
ual training as soon as they join the com- specific operational training when switching individually designed tandem training sessions
pany. But this also bears the risk that, besides to a new machine. in German and English. This approach had
the valuable experience, knowledge gaps the added benefit that only two people were
and misconceptions are also passed on. ever missing from the production area at
Difficult question:
»A FETTE COMPACTING TABLET PRESS HAS OVER What is the function of parameter 66 “number of punches on the turret”?
Answer: d) It defines the number of punches bores which are used to
ONE HUNDRED PRODUCTION PARAMETERS.
calculate the correct machine speed and output of the machine.
BUT WHAT GOOD IS THAT IF ONLY TWENTY OF
THESE ARE USED EFFECTIVELY?« Easy question:
What is the function of the cylindrical height adjustment?
TIM KLINGENHOF, HEAD OF TRAINING AT FETTE COMPACTING Answer: a) To change the tablet hardness
Tableting Tools 26/ 27
THE POWER
OF SEGMENTS
A revolution in tablet production:
Fette Compacting patented Segment technology in numbers Innovations in segment technology
segment technology in 2001.
That’s where the success story of Segments for special geometries
Distribution: Performance: Time-saving:
segments started. Since then Tablets that can be pressed particularly efficiently are usually round and flat, or are
50%
the technology has become slightly convex. This allows for easy filling, dosing, pressing and for optimum
globally one of the most success-
ful and widespread innovations.
It is no longer possible to imagine
40%
proportion of reduction of product
100%
dimensional accuracy
80%
time saving for
yields. But special shapes for the tablet design are popular, and are often chosen
for marketing reasons: They give tablets a unique feature and a recognition
value. For some active materials, the dosing also affects the shape. Domed or
the production of branded segments on loss (max.) compared to dies refitting spherical shapes are necessary if, for example, the tablets are to be coated.
88%
drugs at the big pharmaceutical machines sold Over the years, Fette Compacting has also converted a large number of special
com-panies or at the makers
of generic drugs without segments.
And the success story goes on.
globally
40%
increase in output
300%
increase in service reduction in
geometries to segment technology, and has risen to the challenge of rising
demand.
Fette Compacting is continuously (max.) life through the use manual operations
developing new offers, such as of carbide bushes for refitting Segments for special materials
special geometries or materials. It’s Special materials are sometimes needed for pressing, depending on the nature of
time to look back – and to take the powder and the granulate, particularly when abrasive or adhesive components
a general look at the latest devel- are included. Fette Compacting has developed carbide inserts for segments for
opments in the segments field. just such requirements. This lets users reduce abrasive wear and ensure optimum
tablet quality. The service life of the segments is tripled through minimizing ring
formation and erosion of the walls.
THE DOUBLE-LAYER
WONDER
The user guidance of modern tablet advance for this purpose, using two filling From 35,000 to 99,000 tablets each hour
presses is designed to be highly intuitive. In stations for the double-layer production. In The experience gained on the 3090i provided
this connection, the TRI.EASY concept addition, the first part of the tablet has a good basis for optimizing the process again
from Fette Compacting ensures an optimum received initial pressing before it is combined on the FE75. The filling unit is responsible for
combination of performance and simple with the second component to make a filling the segment holes, and it was changing
operation. It therefore enables efficient tablet- sturdy double-layer tablet. this that made the crucial difference. Gäth
ing. This means that the user does not need suggested that the filling cone system,
to have detailed familiarity with the complex A question of timing available particularly on the FE Series, should
underlying pressing process. This is crucially “The timing and the control rate of the pressing be used. Depending on the tablet size, the
affected by large numbers of parameters force are central control parameters that Tablets flow rate of the material and the production
and machine settings. The Performance Con- affect the properties of the tablet and of the per hour speed, this brings about better filling
99,000
sultants at Fette Compacting are usually entire process at various locations,” ex- properties, and has proven itself particularly
280%
brought in when the process is not running plaines Gäth. In the case of the double-layer useful for large tablets.
optimally. They have succeeded in raising tablet, a whole range of settings were less
the output in the production of a double-layer than optimum on the original machine (3090i). In this way it was possible to increase the
tablet by 180 percent. “It started with the outlet deflector delay output from 35,000 tablets per hour to 99,000
+180%
which was set to a very high figure of ten tablets per hour, without losing any quality.
Jochen Gäth, Performance Consultant at seconds. It went on with the lead time of the Gäth’s summary of potential optimization was
Fette Compacting, remembers his last customer Fill-O-Matic, which was five seconds, and that, “A 180 percent increase in output is
visit in Africa: “Actually I was only there a run-on time of ten seconds, which are not 35,000 nothing rare. The fact is that if appropriate
100%
to optimize the production of an anti-malaria required for normal applications. The control parameters or settings are not optimum, this
product on a new FE75 tablet press.” But lag was also not properly chosen. This can often has fundamental effects.”
since he was in any case already on site, the be used to set when the machine attempts to
Performance Consultant also took on the adjust to achieve the optimum pressing Tablet presses from Fette Compacting are
optimization of another machine. In the process force,” continues Gäth. aimed precisely at the needs of modern
of modernizing the production facility, the Parameter adjustment medication production, and offer the highest
customer wanted to transfer the manufacture All the values were first set to zero in order to possible reliability and performance. The
of a double-layer tablet to the FE75. It find out which parameters were not opti- potential can be increased even further with
was therefore only logical to take a look at the mum. It became clear that the control lag above the help of Performance Consultants.
existing parameters and settings. all was critical for the process flow. The Their expertise provides more efficient pro-
machine had made adjustments too soon and duction, increases the value creation, and In the three-chamber Fill-O-Matic the product
Special features of double-layer tablets they were too much. An adjustment to the allows the processes to be optimized does not flow directly into the dies, but is
Double-layer tablets are most often used when delay is often a central lever for optimizing a continuously. moved through the chambers.
two active ingredients cannot be brought machine. After changing to a control lag of
together in one mixture. This can be the case, ten seconds, the process ran smoothly. The
for example, if the actual medication should parameter adjustment alone achieved an
have a stomach-protecting agent added, or increase of 17 percent in the output (from
when a delayed release of active ingredient 35,000 to 41,000 tablets per hour).
is needed. The machine was fitted out in
Jochen Gäth, Performance
Consultant at Fette Compacing
Fette Compacting around the globe 30 /
30/ 31
NEWS
In May 2019, Fette Compacting China threw An opportunity to exchange ideas and show The largest international product and service
open its doors: Experts from the international appreciation: for the past five years, the providers in the production segment in the
AGILE PHARMACEUTICAL world of pharmacy met at the Customer Center European Union Chamber of Commerce in pharmaceutical industry came together at
PRODUCTION to celebrate the location’s 15th anniversary China has handed out several awards to the pharmaceutical industry’s international
From Vision to Action in the metropolis of Nanjing. A highlight of the European companies operating in China every exhibition FCE Pharma São Paulo, held
anniversary celebrations was the technology year. The non-profit organization issues the between May 21 and 23, 2019. The FCE
workshop at the new Competence Center, awards to acknowledge entrepreneurial Pharma, with over 16,000 visitors, is the only
during which guests discussed new technolo- commitment in the area of corporate social event of this magnitude in South America.
gies and trends in pharmaceutical production. responsibility (CSR). The award ceremony is Every year, the exhibition is used to present
The pharmaceutical industry is faced with major changes: a rapidly a chance to present CSR success stories, trends and innovations in the areas related
growing demand for medication, increasing regulatory require- Fette Compacting has been producing tablet highlight trends and social practices in the to the production chain, such as machinery,
ments, advances in technology, such as continuous manufacturing, presses in Nanjing and offering training since industries and raise awareness of holistic equipment, packaging, quality control,
and much, much more. Times like these demand agile, forward-loo- 2004. Besides the anniversary, the location sustainability. service, and digitalization.
king concepts and actions. What this specifically means will be also celebrated the delivery of the 700th
discussed by renowned experts at the first “Pharmaceutical Circle” locally produced tablet press. Dr. Andreas Around one hundred representatives of This year, Fette Compacting America Latina
at Fette Compacting in Schwarzenbek. This novel event format Risch, Managing Director of Fette Compacting companies, NGOs, social organizations, (FCAL) presented the FEC40 capsule filling
offers the opportunity for a practical exchange of ideas and experiences China, highlighted the location’s continuous governments, media, and schools attended machine to the South American market. The
with representatives from the world of pharmacy as well as other success: “The past 15 years have been an the most recent award ceremony at the FEC40 is ideal for large output quantities
industries. extraordinary story of economic growth as Intercontinental Hotel in Nanjing. of up to 400,000 capsules per hour. Edilson
well as our coming and growing together Fette Compacting China was amongst the Viola, Managing Director of FCAL, recognizes
IS DATA THE NEW MEDICINE? as people.” companies to receive an award, winning the value of the event and concludes: “The
the “MNC – Employee Development Award”. trade fair gave us the opportunity to get closer
WHAT CAN THE PHARMACEUTICAL INDUSTRY LEARN The award acknowledges the multinational to the customer. In the three days, we had a
FROM OTHER SECTORS? company’s commitment to employee devel- vibrant exchange of information, insights, and
opment. experiences with many visitors.”
WHAT ROLE DOES ORAL SOLID DOSAGE (OSD) PLAY
IN A FUTURE OF PERSONALIZED MEDICINE?
A perfectly normal
business call
at Fette Compacting
190902 E
Fette Compacting GmbH Fette Compacting Machinery India Fette Compacting Belgium BVBA
Grabauer Strasse 24 Private Limited Schaliënhoevedreef 1b
21493 Schwarzenbek, Germany A - 406 /407, 4th floor, Atrium 215, 2800 Mechelen, Belgium
Phone +49 4151 12-0 Next to Hotel Courtyard Marriott, Phone +32 15 684260
Fax +49 4151 3797 Near J. B. Nagar Metro station, Fax +32 15 684269
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Andheri (East)
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400 Forge Way Phone +91 22 62763399 Unit 12 Highview
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Phone / Fax +55 19 37969910 Singapore 409837, Singapore dubai@fette-compacting.com
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SA de CV
Adolfo Prieto No. 1638 Fette Compacting Ibérica SL
Colonia Del Valle Sur Avenida Labradores, 1
03100 Mexico, DF, Mexico 2ª Planta, Oficina 3
Phone +52 55 40000653 28760 Tres Cantos, Spain
tablet@fette-compacting.com Phone +34 91 8039689
Fax +34 91 3483052
Fette Compacting (China) Co., Ltd. fcib@fette-compacting.com
No. 9 Shengtong Road, Moling Sub-District,
Jiangning Development Zone, Fette Compacting et
211111 Nanjing Uhlmann France
Jiangsu Province, P.R.C., China 1, Rue du Centre
Phone +86 25 52121818 93160 Noisy Le Grand, France
Fax +86 25 52129951 Phone +33 155 812121
fcn@fette-compacting.com Fax +33 155 812120
contact@fette-uhlmann.fr