Compression- Stages and Tooling

Tablet Production

Powders/granules intended for compression into tablets must

possess two essential properties.
1. Powder fluidity
• The material can be transported through the hopper into the
die.
• To produce tablets of a consistent weight.
• Powder flow can be improved mechanically by the use of
vibrators, incorporate the glidant.
2. Powder compressibility
• The property of forming a stable, intact compact mass when
pressure is applied.
 Tableting Procedure
Tablets are made by compressing a formulation
containing drug or drugs with excipients on stamping
machine called Press. Tablet compression machines
are designed with following basic components-
1. Hopper for holding and feeding granulation to be
compressed.
2. Dies that define the size and shape of the tablet.
3. Punches for compressing the granulation within
the dies.
4. Cam tracks for guiding the movement of the
punches.
5. Feeding mechanisms for moving granulation from
the hopper into the dies.
 Stages of tableting
1. Die filling https://www.youtube.com/watch?v=4xggZRckfTE
2. Compaction
3. Ejection
1- Die filling:

Flow of powders (or granules) of the drug and excipients from a hopper into the die.
The die is closed at its lower end by the lower punch.

2- Tablet formation:

The upper punch descends powder and enters the die and the powder is compressed
until a tablet is formed. lower punch may be stationary or moving upward in the die.
After maximum applied force is reached, the upper punch leaves the die by moving
upward.

3- Tablet ejection:

The lower punch rises up until its tip reaches the die top.
The tablet is subsequently removed by a pushing device.
 Types of Tableting machine
1.Single-punch press:
It is composed of one die and
one pair of punches (up to 100
tab/ min).

2.Multi-punch/ Rotary tablet

press:
It contains ≥60 dies (10,000
tablets/min). It is used for large
scale production.
Multi-station rotary press
 The head of the tablet machine that holds the upper punches, dies and lower punches in
place rotates. A head carrying a number of sets of punches and dies revolves
continuously while the tablet granulation runs from the hopper into the dies. There is a
steel plate revolving under it. This may promotes a uniform fill of the die and therefore
an accurate weight for the tablet.
 As the head rotates, the punches are guided up and down by fixed cam tracks, which
control the sequence of filling, compression and ejection.
 The portions of the head that hold the upper and lower punches are called the upper
and lower turrets.
 The portion holding the dies is called the die table
The pull down cam guides the lower punches to the bottom, allowing the dies to overfill.
 The punches then pass over a weight-control cam, which reduces the fill in the dies to
the desired amount.
 A swipe off blade at the end of the feed frame removes the excess granulation and
directs it around the turret and back into the front of the feed frame.
 The lower punches travel over the lower compression roll while simultaneously the
upper punches ride beneath the upper compression roll.
• The upper punches enter a fixed distance into the dies, while the lower
punches are raised to squeeze and compact the granulation within the dies.
• After the moment of compression, the upper punches are withdrawn as they
follow the upper punch raising cam.
• The lower punches ride up the cam which brings the tablets flush with or
slightly above the surface of the dies.

Smart S Rotary Tablet Press Machine

Mini-press

300,000 tabs per hour

60,000 tablets/ hour
Smart Plus Tablet Press Equipment
Prima Press Rotary Tablet Press

700, 000 tabs per hours

118, 000 tabs per hour
Advanta Press
Plus Double-Slide Tablet Press Machine

630, 000 tabs per hour, both mono-layer

and bi-layer tablets.
 Tablet press tooling
• A tooling set comprises the die and its associated punches.
Punches and dies are essential tools in the tableting process and
therefore are critical to the quality of the tablets produced.
• Both tools are designed for long life under normal conditions of
working.
Tablet Specification Manual (TSM) for American standard, Euro
Standard (EU) for the European market, TDP & RTP standard.
Basically, there are two types of tooling's:
1. “B” type
2. “D” type
• The B tooling dies and punch can be further have specifications
as BB and D tooling can also be dies and punches can be utilsed
on B tooling machine which is called as DB
1. Head: The end of the punch that guides it through the cam track of tablet machine
during Rotation.
2. Head flat (Dwell Flat): The flat area of the head that receives the compression
force from Rollers (in upper punches) and determines the weight and ejection
height (in lower punches).
3. Outside head Angle: The area gets in touch with the roller prior to head flat , while
Compression.
4. Inside Head Angle: This is the area, which pulls down the lower punches after
ejection and lifts the upper punches after compression.
5. Neck: The relived area between the head and barrel, which provides clearance for
the cams.
6. Barrel: This area guides the punch (while going up and down) with reference to
turret guides.
7. Stem: The area of the punch opposite the head, beginning at the tip and extending
to the point where the full diameter of the barrel begins. If the chamfer is present
the barrel usually reaches its full diameter just above the chamfer.
8. Tip: This determines size, shape & profile
9. Tip face: This area of punch is where the tablet is formed. Good surface finish is
required here to get quality tablets.
10. Working length: This distance between bottom of the cup and the head flat is
called as working length which determines weight and thickness of the tablet.
11. Overall length: Distance between top of the cup and the head flat.
12. Key Angle: The relationship of the punch key to the tablet shape. The keys position
is influenced by the tablet shape, take-off angle, and turret rotation.
 Max. Tab.
Type Punch Lengt  Punch Diam Die Diameter Height of size (mm)
of Tooling ( mm) (mm) (mm) dies (mm) Round/Capsule
 
B 133.6 19 30.15 22.22 16/19
D 133.6 25.4 38.1 23.82 25/25
BB 133.6 19 24.0 22.22 13/14
DB 133.6 25.4 30.15 23.22 19/19

Multi-Tip Tooling
Multitip Tooling are tools manufactured
with more than one tip and number of
tips range from 2 tips to in excess of 15
tips based on size of tooling. The major
advantage is increase in productivity and
reduction in runtime.