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ADEPT TABLET PRESS
Group History

• 1968
  – Started in a workshop of 20 sq. mtr with 6 people
    manufacturing punches & dies
• 1987
  – Introduced Adept Tablet Press
• 2006
  – Started representing European machine
    manufacturers in India
Current Scenario

• Annual capacity of 30 tablet presses & 12000
  tooling sets
• Export to over 35 countries
• More than 50% production exported
• More than 350 Tablet Press Machines in the
  market
Achievements

• Major developments
   – Higher Station Turrets
   – R&D Turrets
   – ‘A’ Tooling 59 station press


• Only Indian Tool Mfr. to be mentioned in TSM [4th
  Edition] as ‘Reviewer & Contributor’
• Approved global tooling vendor for Sanofi-
  Aventis
• Leading tooling exporter
Regular Clients – Adept Press
•   Agog Pharma        •   Suntrition – Canada
•   Blue Cross         •   Kina Pharma – Ghana
•   Flamingo Pharma    •   Lab & Allied – Kenya
•   Fredun             •   Ultra – Mexico
•   Maneesh Pharma     •   Duo Pharma – Malaysia
•   Shreechem Pharma   •   Juhel – Nigeria
•   Shreya             •   May&Baker – Nigeria
                       •   Diod – Russia
                       •   Aras Gida – Turkey
                       •   Concord Labs – USA
Double Sided Tablet Press
Design Objectives

•   Ease of Use
•   Sturdiness / Diverse Application
•   Low Maintenance And Minimum Downtime
•   Other Features
•   Maximum Output
Ease of Use
Front Control

• Calibrated Control Knobs
• Pressure and weight setting from outside the
  machine
Variable Frequency Drive

• Speed Control
• Soft Start
Auto Lubrication
PLC Control (Optional)

• Controls
   – Main Motor & VFD
   – Lubrication System
• Displays
   – Machine interlock status
   – Tablet Counting
• Stores
   – Recipe
   – Batch Data
Diverse Application
Compresses all types of tablets

• High Load Bearing Capacity: useful for Big tablets
  & Low Compressibility product
   – Height less by 20cms
   – Double ‘V’ Belts
   – 5HP Motor and 5HP VFD
• Compression Type Spring
   – Useful for making small tablets
   – Can apply minimum 1 Ton pressure
• Can also be used as single sided press with pre-
  compression and double fill station
   – Useful for compressing fluffy powder
Compression Level Adjustment

• Useful in changing the compression level of the
  tablet in the die
• Useful in reducing Capping and Ejection Force
• Useful in making bi-layer tablet
Bi-Layer Tablets

• This is accomplished by Just changing the feed
  frames and removing one lower punch cam.
Low Maintenance And
 Minimum Downtime
Special Turret

• 50 grade casting instead of 35 grade casting
    – Prevents cracking of die table
    – Increases tensile strength
•   Use of smaller size bolt for die locking of BB dies
•   Thrush bearing
•   Detachable gear ring
•   Nickel plating (Optional)
Lower Roller Fitted with Bearing

• Reduces wear on lower pin
• Reduces roller jamming
Feed Frame Brackets

• Feed frame brackets are independent of Turret
  Guards
Window in Worm Housing

• Gives a visual check on the condition of the
  worm
Upper Roll Replacement

• Upper roll can be replaced in 5minutes
Other Features
OTHER FEATURES

LOAD INDICATION
•Calibrated Metal Label for pressure setting
•Gives an indication of applied load

TUNNEL TRACKS
•Double support to upper punches
•Reduces chances of accident

DOUBLE KEYWAY IN CAM PLATE

DRIVE SHAFT OF ALLOY STEEL
Better Compliance
GMP Compliant

• Contact parts of S.S. 316
• All non-contact parts in compression zone are
  Electroless Nickel Plated / Hard Chrome Plated
• S.S. fabrication done using Laser Cutting &
  Bending

CE Complaint [optional]
Maximum Output
Feeder of Food Grade Polymer

• Minimises weight variation
• Increases production
• Spring loaded scraper blade
Higher number of Stations

• 27 in D Tooling
• 59 in A Tooling
Technical Details
Models




• With special turret and one side as pre-
  compression
Adept Double Rotary Press

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Adept Double Rotary Press

  • 2. Group History • 1968 – Started in a workshop of 20 sq. mtr with 6 people manufacturing punches & dies • 1987 – Introduced Adept Tablet Press • 2006 – Started representing European machine manufacturers in India
  • 3. Current Scenario • Annual capacity of 30 tablet presses & 12000 tooling sets • Export to over 35 countries • More than 50% production exported • More than 350 Tablet Press Machines in the market
  • 4. Achievements • Major developments – Higher Station Turrets – R&D Turrets – ‘A’ Tooling 59 station press • Only Indian Tool Mfr. to be mentioned in TSM [4th Edition] as ‘Reviewer & Contributor’ • Approved global tooling vendor for Sanofi- Aventis • Leading tooling exporter
  • 5. Regular Clients – Adept Press • Agog Pharma • Suntrition – Canada • Blue Cross • Kina Pharma – Ghana • Flamingo Pharma • Lab & Allied – Kenya • Fredun • Ultra – Mexico • Maneesh Pharma • Duo Pharma – Malaysia • Shreechem Pharma • Juhel – Nigeria • Shreya • May&Baker – Nigeria • Diod – Russia • Aras Gida – Turkey • Concord Labs – USA
  • 7. Design Objectives • Ease of Use • Sturdiness / Diverse Application • Low Maintenance And Minimum Downtime • Other Features • Maximum Output
  • 9. Front Control • Calibrated Control Knobs • Pressure and weight setting from outside the machine
  • 10. Variable Frequency Drive • Speed Control • Soft Start
  • 12. PLC Control (Optional) • Controls – Main Motor & VFD – Lubrication System • Displays – Machine interlock status – Tablet Counting • Stores – Recipe – Batch Data
  • 14. Compresses all types of tablets • High Load Bearing Capacity: useful for Big tablets & Low Compressibility product – Height less by 20cms – Double ‘V’ Belts – 5HP Motor and 5HP VFD • Compression Type Spring – Useful for making small tablets – Can apply minimum 1 Ton pressure • Can also be used as single sided press with pre- compression and double fill station – Useful for compressing fluffy powder
  • 15. Compression Level Adjustment • Useful in changing the compression level of the tablet in the die • Useful in reducing Capping and Ejection Force • Useful in making bi-layer tablet
  • 16. Bi-Layer Tablets • This is accomplished by Just changing the feed frames and removing one lower punch cam.
  • 17. Low Maintenance And Minimum Downtime
  • 18. Special Turret • 50 grade casting instead of 35 grade casting – Prevents cracking of die table – Increases tensile strength • Use of smaller size bolt for die locking of BB dies • Thrush bearing • Detachable gear ring • Nickel plating (Optional)
  • 19. Lower Roller Fitted with Bearing • Reduces wear on lower pin • Reduces roller jamming
  • 20. Feed Frame Brackets • Feed frame brackets are independent of Turret Guards
  • 21. Window in Worm Housing • Gives a visual check on the condition of the worm
  • 22. Upper Roll Replacement • Upper roll can be replaced in 5minutes
  • 24. OTHER FEATURES LOAD INDICATION •Calibrated Metal Label for pressure setting •Gives an indication of applied load TUNNEL TRACKS •Double support to upper punches •Reduces chances of accident DOUBLE KEYWAY IN CAM PLATE DRIVE SHAFT OF ALLOY STEEL
  • 26. GMP Compliant • Contact parts of S.S. 316 • All non-contact parts in compression zone are Electroless Nickel Plated / Hard Chrome Plated • S.S. fabrication done using Laser Cutting & Bending CE Complaint [optional]
  • 28. Feeder of Food Grade Polymer • Minimises weight variation • Increases production • Spring loaded scraper blade
  • 29. Higher number of Stations • 27 in D Tooling • 59 in A Tooling
  • 31. Models • With special turret and one side as pre- compression

Editor's Notes

  1. Hello Friends, Today I am here to talk about the Rotary Tablet Press. But before I begin, I must admit to you that I am not a good speaker. Hence I would prefer it to be an interactive session rather than a speech. So at any point if you have any clarifications, questions or observations please do not hesitate to ask me right then.
  2. What I will cover in today’s presentation are the important machine parts and what role each of them plays. However, for the benefit of my young friends, who were not around at that time, I would like to quickly take you through the evolution of the tablet press.
  3. In the early days, the single stroke press was manually operated and the output was about 150 tablets per hour. Later it was motorized and the output increased to 900 tablets per hour.
  4. After that the 16 station single sided rotary press was introduced and this gave an output of 19,000 tablets per hour
  5. Finally the 27 station double sided rotary press was introduced which gave an output of 100,000 tablets per hour. The same machine was enhanced to 45 station by developing smaller tooling called BB tooling which enabled an output of 160,000 tablets per hour running at a speed of 30 RPM.
  6. And the latest in Rotary Tablet Press are electronically instrumented presses which can run at 60-90 RPM and give an output of 500,000 tablets per hour. In fact the Korsch XL-800, 95 station press can give an output of 1,000,000 tablets per hour.
  7. Now we will get to the main section of the presentation. What I will do is to take you through the important parts of the Press and for every part I will try and explain its: Function Importance Benefits Setting Inspection & Maintenance Common problems Recent developments
  8. A turret is made of cast iron. Different grade of casting has different tensile strength. Usually 35 grade casting is used; 35 grade means 35 kg per square mm tensile strength. Nowadays nickel plated turrets are also common. These are vey useful for corrosive products as they are anti rusting.
  9. Crack in between two dies is the most common problem – this problem is especially noticed on BB tooling. On higher station turret gap between 2 dies is less. For example on 45 station, gap is 2.5mm whereas on 41 station gap is 4.5mm. The less gap causes crack between dies. The other reason is over tightening of the die-locking screw. This can be avoided by using a torque wrench. This will prevent excess pressure on the turret. The other way to avoid the cracking can be by requesting for a 50 grade casting as it will give more tensile strength. Also if smaller sized alen bolt is used for BB die locking then it reduces the pressure on the turret. Most press manufacturers use 5/8 inch alen bolt for D,B and BB dies; however as per my experience half inch alen bolt is sufficient to lock B and BB dies A three piece turret is another solution to this problem. In this the center piece is made of SS rolled plate. This is because rolled material gives higher tensile strength compared to cast material. SS is also beneficial for corrosive products, as it is anti rust.
  10. Conventional machines can be changed to higher stations to get more production. For example a 16 stations D tooling turret can be changed to a 32 station BB tooling turret. This will give double production on the same machine. Similarly 27 station B tooling turret can be changed to 45 station BB tooling, which will give 65% more production In the same sequence 27 station B tooling turret is changed to 59 station A tooling, which gives 120% more output. Till date we have successfully upgraded over 200 turrets