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Compression Basic

A compression machine consists of a hopper, dies, punches, and cam tracks. It works by filling the dies, dosing excess powder, compressing the powder between the punches to form tablets, then ejecting the tablets. Key parameters include turret speed, feeder speed, die fill depth, and compaction forces. The machine operates in different modes like auto, manual, and product mode. Sensors provide feedback to control tablet weights and maintain consistent compression forces. Common issues like weight variations, breaking, or capping can arise from factors like granule properties, speed, moisture levels, or pressure settings.

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EKA NURUL FALAH 02511740000082
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947 views24 pages

Compression Basic

A compression machine consists of a hopper, dies, punches, and cam tracks. It works by filling the dies, dosing excess powder, compressing the powder between the punches to form tablets, then ejecting the tablets. Key parameters include turret speed, feeder speed, die fill depth, and compaction forces. The machine operates in different modes like auto, manual, and product mode. Sensors provide feedback to control tablet weights and maintain consistent compression forces. Common issues like weight variations, breaking, or capping can arise from factors like granule properties, speed, moisture levels, or pressure settings.

Uploaded by

EKA NURUL FALAH 02511740000082
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 24

COMPRESSION MACHINE

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CONCEPTS
 Definition

Types Of Compression Machine

Parts Of Compression Machine

Basic Principle Of Compression

Working Principle Of Compression Machine

Critical Parameters

Sensors & Safety Features Of Compression Machine

2
DEFINITIONS
Tablets are made by compressing a formulation containing a
drug or drugs with excipients on stamping machines called
Compression Machine.

There are several categories of tablet


• Uncoated tablets
• Coated tablets
• Effervescent tablets
• Dispersible tablets
• Soluble tablets
• Oro dispersible tablets
• Gastro resistant tablets
• Modified tablets

3
Types Of Compression Machine

Single Punch Tablet Press

Multi Station Rotary Tablet Press

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Single Punch Tablet Press
 It is called a single-punch tablet press as it makes one tablet at a time.

 In single punch machines, all of the compression is applied by the upper punch

Multi Station Rotary Tablet Press


 steps involved are:

Over fill Corrected Fill Compression Ejection

 Termed As rotary because the head of the machine (Turret) that


holds the upper punches, dies and lower punches rotates.

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Parts OF Compression Machine
1. Hopper
 for holding and feeding granulation

2. Dies
 define the size and shape of the tablet

3. A feeding Mechanism
 moving granulation from hopper into the dies

4. Punches
 for compressing the granulation within the dies.

5. Cam tracks
 for guiding the movement of the punches.

7
Basic Principle Of Compression

Filling of the Dies

Dosing Of Dies

Compression of the Tablets

Ejection and Exit of the Tablets

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Filling Of Die
 The material to be pressed reaches the feeder from the Hopper.
 The fill cam below the feeder pulls the lower punches down by a fixed amount and the dies are
filled with material.
 The quantity of the material filled is larger than the actual amount required
i.e. excess dosing is done.

Dosing Of Die
The dosing unit lifts the lower punches until only the desired quantity of material remains in the
dies. The excess material is transported back into the feeder.

Compression
After that, the upper cam course lowers the upper punch until the upper punches are inserted into
the dies. The lower punches are guide to the pre-compression roller. When the punches pass the
pre-compression roller, they are inserted a little more into the dies and the material is pre-
compressed and the slugs are formed. Thereafter, in the main compression roller, the tablets
reach their final height and hardness

Ejection & Exit


After the compression, the upper cam course pulls the upper punches into their top position
and simultaneously the ejection device lifts the lower punches until the tablets are ejected from
the dies. The tablet stripping device strips the tablets off the lower punches and passes them
on to the discharge chute.

9
The stages in the compression cycle are shown in figure.

• Stages 1 and 2 in demonstrate filling and dosing of the dies.

• Stage 3 demonstrates the compression of the tablets.

• Stage 4 demonstrates the ejection and exit of the tablets.

• Stage 5 demonstrates the start of next cycle.

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COMPRESSION TECHNIQUE

Following Defect /trouble shooting Found During tablet compression


TROUBLE POSSIBLE CAUSE ACTION
Inconsistent weight 1. Variation in punch length 1. Replace the punch with correct one
2. Improve granules / mixing technique
2. Inconsistent granule 3. Check hopper /adjust the flow of
powder.
3. Empty force feeder 4. Replace

4. Brake plugs worn out 5. Reduced the speed of machine.


6. Adjust the material flow.
5. Dies not filled

Double impression 1. Worn out brake plugs 1. Replace


2. Excessive pre pressure 2. Decrease pre pressure.

Variation in thickness / hardness 1. Weight variation 1. Same as above


2. Worn pressure roll 2. Replace
3. Variation in punch length 3. Replace
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COMPRESSION TECHNIQUE

TROUBLE POSSIBLE CAUSE ACTION


Tablet breaking on take 1. Take of plate incorrectly set. 1. Check and reset
off 2. Lower punch ejection height incorrect. 2. Check and reset
3. Speed of machine to high.
3. Reduced speed of machine to get the
4. Granules to dry correct tablets
4. Increase the moisture level
5. Soft tablets
6. Scraper not set proper as per shape of 5. Check and set the hardness
tablets 6. Check and reset the scraper

Excessive material loss 1. Incorrect set of the feed frame 1. Check and reset
2. Upper punch penetration set to high 2. Check and reset
3. Inadequate dust extraction point 3. Reset
4. Excessive clearance between lower punch 4. Replace
tip to die bore

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TROUBLE POSSIBLE CAUSE ACTION

Capping / laminating 1. Granules to dry 1. Increase moisture level high


2. Reduce the speed of machine
2. Machine speed to high 3. Reduce the hardness within
allowable limit
3. Excessive pressure ( high hardness) 4. Apply require pressure
4. Pressure not given . 5. Set the punch penetration and try to
5. Tablets compressed in die at lower compressed the tablets at upper side
of the die.

Black particle 1. Excessive Lubrication 1. Check an set the require time


interval
2. Friction of parts which generate the 2. Check and reset.
particle
3. Dust cap filled with granules 3. Clean the dust cap.

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COMPRESSION TECHNIQUE

Some tablets Defects

Black particle Broken tablets Sticking

15
COMPRESSION TECHNIQUE

Some tablets Defects

Capping /laminating

Edges /chipping Rough surface

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Working Principle of Cadmach CTX IIA Compression Machine

 Operated On SCADA

SCADA
Supervisory Control And Data Acquisition
 SCADA is a system operating with coded signals over communication channels so as to
provide control of remote equipment

 A tablet press can be instrumented with a strain gauge that senses and reacts to compression force
changes. (CFC)

 Compression force fluctuation is the result of slight changes in tablet weights. As the tablet weights
increases the compression force increases and as tablet weights decrease the compression force decreases.

 As blended powders are being compressed there is a consistent and measurable force rhythm that is
detected using a strain gauge. The strain gauge sends a signal to control the volumetric powder fill level
(weight adjustment cam), which controls tablet weights.

17
Operation OF Machine
Machine should run in 5 mode

 Auto Run

 Manual Run

 In this Mode Turret & Feeder Jog, Turret Jog, Feeder Jog, Lubrication Jog Should Be done.
 Before Setting By this Mode Feeder should be fill.

 Test Run

 Setup Mode

 In This Mode All Function Can Be Change


 For Initial Setting of machine

 Product Mode

 In This Mode Some Function Can not be Change


 After Batch Setting Machine Run run In this mode

18
Parameters Of Machine
 Turret Parameter
In Which Following Parameter included
 Speed (12 to 70 RPM)
 Machine Guard Mode (By pass or Auto)
 Hour Meter Mode (On / OFF)
 Mode Of Dummy Punch (By Pass or Auto)

 Force Feeder Parameter


In Which Following Parameter included
 Speed (10 to 50 RPM)
 Synchronized Speed Mode (By pass or Auto)
 Feeder Pre Run Time (0 to 99 Sec.)
 Feeder Post Run Time (0 to 99 Sec)

 Depth Of Die Fill Parameter


In Which Following Parameter included
 Depth Of die Fill

 Tablet Thickness Parameter


In Which Following Parameter included
 Upper Punch Pre Pressure
 Upper Punch Main Pressure
 Tab. Cylindrical Height Pre Pressure
 Tab. Cylindrical Height Main Pressure

19
 Compaction Force Parameter
In Which Following Parameter included
 Main Compaction Force Avg.
 Compaction Force Control Mode (On /OFF)
 Ind. Main Compaction Force limit Max (5 KN More than max Value of compaction force)
 Main Compaction Force SD Limit Max%
 Force Control Limit low(Should Be 0.25 KN Less Than Min Compaction Force)
 Force Control Limit Max (Should Be 025 KN More Than Max Compaction Force)
 Ind. Rej. Force Limit low (Should Be 2 to 3 KN Less than Min Compaction Force)
 Ind. Rej. Force Limit Max (Should BE 2 to 3 KN More Than Max Compaction Force)

 Sampling & Rejection Parameter


In Which Following Parameter included
 Initial Tablet Rejection ON Time (0 to 999 Sec)
 Mode Of Sampling (Off, Selected Punch , No Of Tablets, All Tablets In Continuous Mode)
 No Of Tablets For Sample
 Interval Time For Tablet Sampling (0 to 7200 Sec)
 Punch No For Tablet Sample 1 to 5
 Permitted Rejected Tab / Revaluation (1 to 37)
 Lubrication Parameter
In Which Following Parameter included
 Lubrication ON Time (0 to 60 Sec)
 Lubrication OFF Time (30 to 500 Min)

20
Load Cell
Two Types
Compaction Force Load Cell

Ejection Force load cell

21
Graphs
Two Types

 Bar Graphs

 Trends Graphs

22
Safety Features
 Emergency Button release
 Turret Motor Healthy
 Feeder Motor Healthy
 Hydraulic Motor Healthy
 Lubrication Motor Healthy
 Main Hydraulic System Pressure Within Limit
 Hydraulic oil Level
 Lubrication Oil Level
 Air Pressure Low
 Machine Guard Open
 Hand Wheel Guard Open
 Door For Electrical Panel Box
 Punch Entry Piece In Position
 Batch Size Continuous
 Batch No Entered
 Powder level
 Ind Main Compaction Force Within Limit
 Ind tab. Ejection Force Within Limit
 Tab. Counting Proxy

23
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