How High Speed Tablet Press Bring You Benefits beyond Output?

A tablet press is a machine engineered to compress powdery and granular substances into round, oval, or irregularly shaped pills, an essential function for pharmaceutical tablet manufacturing and dietary supplement production. In each cycle of pressing tablets, an upper punch rod and a lower punch rod dive into the same die hole to compress powdery ingredient into a tablet within a die hole.

High output seems to be the most outstanding feature of a high speed tablet press. Besides the impressive production capacity, how can this automated pill press save your cost and constantly bring you more benefits? We first describe the pill pressing machine categories, then have insights into features of high speed pill presses that create superior advantages. If you’re seeking a pill and tablet press, this article may give you wiser selections.

the main mechanism (punches and a turret) of a high-speed rotary pill maker press

1. Pill Press Machine Classification According to Structures

Pill press tablet press machines are classified into 2 varieties according to their mechanical structures and motion forms.

1.1 Single Punch Mini Pill Press

A single-punch mini tablet press is a chemical or pharmaceutical tablet making machine that compresses powder or granules into tablets via only one upper and one lower punch. It’s used for small-batch tablet production, lab research, or pilot-scale testing, usually applied in pharmacies, laboratories, and some small workshops.

1.2 Rotary Tablet Press Machine

A rotary pill tablet press machine is specially designed for large-scale tablet manufacturing, capable of producing hundreds of thousands of nutraceutical or pharmaceutical tablets per hour by adopting a rotating turret equipped with dozens of punches and dies. In addition, a rotary tablet manufacturing machine operates in an automatic method, significant for efficient tablet pressing.

2. Tablet Compression Machine Classification According to Speed

In terms of rotary models, tablet pill press machines are classified into 2 varieties according to their operational speed.

2.1 Medium- and Low-speed Pill Press

The round turret, which incorporates all dies and in certain cases bears compression force of punch rods, is one of the most critical components of an automatic rotary tablet press machine. Pill maker tablet presses with turret rotation speed lower than 30 rounds per minute (RPM) are classified as low-speed models, while those with turret rotation speed ranging from 30 to 50 RPM are categorized as medium-speed pill compressors. Typically, the production output of a low speed small scale tablet press ranges from 13,200 to 37,800 tablets/hour.

2.2 High Speed Tablet Press

A model with a turret rotation speed exceeding 50 RPM is categorized as a high speed tablet press machine. Take HGZP 26-40D model for an example. With a max turret speed reaching 110 RPM, this high speed rotary tablet press can automatically output up to 260,000 tablets per hour, ideal for large-scale pharmaceutical tablet manufacturing.

Reviewing high-end pill press machines manufactured by top-tiered pharmaceutical machinery suppliers such as IMA, Romaco, and Rich Packing, the max output of a high speed tablet press can reach 960,000 tablets per hour.

Beyond high output, what advantages does a high speed tablet press bring about? How can this machine save costs in your long-term tablet production? We will dive into advanced pill maker features.

3. What Extra Benefits Do High Speed Tablet Presses Offer?

Compared to low speed models, a high speed pill presser does offer multiple extraordinary benefits that tightly matter with tablet quality, downtime reduction, prolonged equipment lifespan, regulatory compliance, etc. Besides high output, we will mention 5 critical benefits:

1) Precise tablet weight control

2) Tooling changeover convenience and downtime saving

3) Automatic lubricating method and extended machine life

4) Dust-free tablet compression and material saving

5) Noise reduction during tablet pressing

3.1 Uniform Tablet Weight: Real-time Auto Control VS Manual Control

Most high speed tablet presses nowadays at market enjoy real-time, automatic, and precise tablet weight control, while medium or low speed tablet compressors rely on manually adjusting tablet weight via handwheels.

Via a touchscreen, parameters can be adjusted and pressure can be monitored.

When it comes to tablet weight uniformity, cGMP standards set clear requirements for managing tablet weight: It is mandatory to ensure consistent tablet weight to guarantee batch uniformity and content accuracy. Pill press tablet manufacturers are required to achieve this through tablet production process monitoring, which determines that rotary tablet presses must possess high precision and automation in tablet weight control.

For meeting cGMP requirements, tablet press manufacturers engineer high speed pill pressers that carry out real-time tablet weight control during processes of pressing pills. This control is achieved via 3 functions:

● Real-time Compression Force Monitoring

During tablet compression, sensors installed on compression rolls and punch rods measure the force borne by each punch in real time. Abnormal fluctuations in compression force exist as early indicators of tablet weight deviations. For instance, a sudden drop in pressure may indicate insufficient powder fill volume, resulting in underweight medication tablets, while a sudden increase in pressure suggest excessive fill volume, leading to overweight drug tablets.

● Automatic Fill Volume Adjustment

This function relies on pressure feedback. If sensors detect compression force deviation from the target value, the system via servo motors instantly issues a command to auto make subtle adjustments to the fill depth of the feeder. This adjustment increases or decreases the powder volume in die bores, bringing the pressure back to the set value, thereby realizing consistent tablet weight.

● Automatic Waste Rejection

This system automatically identifies any tablet that deviates from the set pressure parameter and precisely rejects it. By continuously removing individual underweight or overweight tablets, an auto tablet press machine ensures finished drug tablets of consistent weight.

On some medium and low-speed pill tablet presses, functions above may be optional features. Many of these models still rely on periodic sampling, weight checking after tablet prooduction, and manual adjustment, considered as a risk area in cGMP audit. In contrast, high speed pill presses generally enjoy punch force monitoring and auto powder fill volume adjustment, representing a shift from post-production testing to real-time process control.

3.2 Save Downtime: Tool-free Mold Changeover VS Tool-dependent Mold Replacement

As a pharmaceutical manufacturer, you are manufacturing several or even multiple types of tablets. Every time before you press another type of tablets, you need to change over your molds including punch rods and dies for cleaning and applying new shapes to pharmaceutical tablets, resulting in press tablet machine downtime. To reduce downtime, many high speed rotary tablet presses possess the function of tool-free mold change, helping replace tooling within 30 minutes.

tool-free mold changeover with bare hands

A high speed rotary tablet press machine with quick-release modular design, such as HGZP 15-20D, allows for die and punch changeover with bare hands, significantly reducing machine downtime. Moreover, since tools are not required for striking or prying dies and punch rods, the precision and service life of molds are better preserved.

By contrast, most low-speed medicine tablet machines lack the function of tool-free mold changing. Instead, tools such as hammers, jacks, and wrenches must be used to disassemble dies and punches by striking them. Consequently, this striking easily squeezes out metal debris, involves high labor intensity, and results in prolonged downtime. Furthermore, long-term striking deforms round die bores into oval die holes, leading to loss of tooling precision and disrupting the tablet manufacturing process.

Thanks to the tool-free mold replacement, if you apply a high speed compression machine for tablets to tablet manufacturing, at least 2 hours can be saved in each turn of mold changeover. Assuming molds need to be changed once a week, and there are around 50 weeks per year, a total of 100 hours can be saved on mold changeover annually. With a production rate of 150,000 medication tablets per hour, the time saved would allow for an additional 15 million pharmaceutical tablets to be produced in a year.

3.3 Extend Equipment Lifespan: Intelligent Lubrication VS Manual Lubrication

Intelligent lubrication systems are commonly found in high-speed tablet compressors. This feature is also a standard configuration in modern high-performance rotary tablet machines. However, in frequent cases of using a low speed model, users need to manually lubricate.

An built-in intelligent lubrication system employs automatic control technology to deliver lubricant precisely to the required components in a timed and measured manner. Based on continuous working, it lubricates equipment parts without stopping the tablet production, ensuring an uninterrupted tablet manufacturing process. Furthermore, intelligent lubrication prevents equipment wear caused by oil supply interruptions, extending the service life of critical components such as compression rolls, punches, and tracks. Thanks to automated and precise lubricating, it also reduces labor and lubricant consumption costs.

Conversely, manual lubrication is prone to uneven lubricant distribution due to human factors, often resulting in over- or under-lubrication. Additionally, it requires machine shutdown, which impedes tablet compression efficiency. What’s more, this method is heavily reliant on operator diligence, and inadequate lubrication leads to component wear, reducing the lifespan of a pharmaceutical tablet compression machine.

3.4 cGMP Compliance: Controlling Excessive Powder & Dust

In traditional tablet compression operations, the uncontrolled escape of powder within the compression chamber is a common challenge. This phenomenon results in powdery ingredient loss and product cross contamination, and conflicts with cGMP requirements.

To address this issue, a modern high speed tablet compression machine can integrate multiple engineering solutions to achieve powder and dust containment. 4 key mechanisms are employed for powder and dust control: 

●Fully Enclosed Forced Feeder

It replaces open feeders in traditional low-speed pill making machines. This sealed system ensures powder is loaded and forced into die cavities without exposure. A meticulously maintained gap of ≤0.05mm between the feeder base and the turret further prevents powder leakage.

an enclosed forced feeder (left) and a powder suppression blade (the white on the right)

●Powder Recovery Device

This device captures residual powder that escapes the feeder. With the help of the turret’s drive, this mechanism recycles excess powder for reuse, maintaining a clean turret surface and minimizing powder waste.

●Powder Suppression Blade

Strategically positioned on the turret between the feeder and the point where upper punches enter die bores, this blade physically prevents powder from being ejected from die cavities due to the rapid turret rotation.

●Dual-extraction Dust Removal Device

Features a mechanism of at least 12 suction ports positioned around the turret's perimeter, this device actively captures powder or dust that escapes other containment measures.

Collectively, this integrated powder control system transforms high-speed tablet compression from a dusty operation into a clean tablet manufacturing process.

3.5 Lower Noises: Damping Mechanisms

To reduce the punch wear and operating noise, damping mechanisms are standard in high speed rotary tablet compression machine. While less common on low-speed models, they are expected to gradually gain popularity.

upper and lower punch rods

●Flexible Damping Mechanism

Fitted around punch rods, these components utilize elastic materials to absorb vibrational energy. By dampening vibrations traveling through the machine frame, they effectively prevent these vibrations from becoming airborne noise.

●Magnetic Damping Mechanism

This system creates a contactless braking force. Fixed magnets are positioned near the ends of punches' travel paths, interacting with magnets on punches to generate a repulsive force. This results in a gradual deceleration and a "soft stop," eliminating the impact noise typically caused by mechanical collisions.

These damping structures absorb the impact energy from punches colliding with turret guides, reducing noise by approximately 25 dB and creating a healthier environment for pill press operators. They also diminish impact forces, minimizing metal debris generated by metal friction and extending the service life of tooling. However, manufacturers of traditional low-speed pill presses typically do not adopt damping mechanisms as a standard feature in order to cut costs.

Conclusion

As you hesitate between a high speed tablet press and a medium/low speed model, consider more beyond the initial price and your output demand. An all-round assessment of cGMP compliance, tablet weight control, operational efficiency, downtime reduction, equipment lifespan preservation, cost conservation, etc. is necessary. Pay attention to these key areas guides you to a pill machine that guarantees quality of your pharmaceutical tablets and sustainable, long-term value.