Pharmachine India

Vikhroli, Mumbai, Maharashtra

The Ultrasonic Punch & Die Cleaning Machine offers effective and consistent cleaning without manual intervention. Even the most delicate part of the punch, i.e. the tip, is cleaned of all the deposits without risk of deterioration. Difficult areas like intricate embossing and inside of die are cleaned with same efficiency. It also reduced chances of damage as manual handling is minimised.

The cleaning time per set is just about 1:20 minutes. Punches and dies are accommodated on specially designed fixtures. These are then passed through 4 stages:

• Ultrasonic cleaning
• Ultrasonic rinsing
• Drying
• Rust Prevention

If the punches are to be used after cleaning then the rust prevention stage can be avoided. The machine is

Semi Automatic with Manual Loadingalso available in:

• Table Top model

Auto Punch Polisher helps improve the surface finish of punches, which leads to improved tablet finish, minimises sticking and prevents corrosion.

During tablet production, punches and dies lose their original finish due to abrasion and powder sticking. At present these are normally cleaned by manual polishing, which is a time consuming process and the finish depends on operators skill.

The Auto Punch Polisher minimises dependence on operator skill and increase productivity by 20 times. The machine is fitted with a PLC that allows the user to program the complete cycle.

Most punches are damaged in handling rather than while production. And to ensure safe storage and handling of punches we have created a safe storage cabinet for your tooling. Not only does it keep your tools safe, but it also makes optimum use of space, making the cabinet an essential commodity. It offers benefits like:

• Systematic, Indexed storing of tools
• Protection from dust, dirt, moisture and mishandling
• Compact design, thereby freeing your floor-space
• Capacity - 384 sets of 'D' tooling or 576 sets of 'B' tooling

The Adept Mega Press is designed keeping in mind Adept's philosophy of providing simple and efficient solution. The Adept Mega Press not only gives a higher output but also guarantees minimum breakdown and maintenance. Special emphasis has been given on trouble free working and durability so that the machine can be used in a 24/7 working environment.

Center Drive

• The machine has true center drive, unlike the internal helical gear ring system.
• There is no worm and gear ring on the turret mechanism thereby reducing moving parts and minimising maintenance.
• Gear box is directly coupled to center shaft with a keyless coupling to ensure zero backlash.

Hydraulic Power Pack

• The compression springs are replaced by compact hydraulic power packs.
• This system also acts as an overload release mechanism and can be used to measure the applied pressure in tons.
• Pressure is applied directly on the compression axis ensuring more unifrom pressure.

Hydraulic Power Pack

• The compression springs are replaced by compact hydraulic power packs.
• This system also acts as an overload release mechanism and can be used to measure the applied pressure in tons.
• Pressure is applied directly on the compression axis ensuring more unifrom pressure.

10 Ton Pre Compression

• Adept Mega Press is designed for 10 tons pre-compression load. The pre-compression pressure is also hydraulic.
• Rollers are fitted with high load capacity bearings, which do not require continuous lubrication.
• Rollers are of double thickness to increase dwell time.
• All 8 rollers are identical and interchangeable.

Feeder System

• Machine is fitted with a 3 chamber bottom driven rotary feeder.
• The Rotary Feeder has an individual motor and A.C. Drive.
• An overflow indicator is provided in the rotary feeder to prevent jamming due to excess flow.
• The Adept Mega Press is also provided with a multi-chamber gravity feeder that is made of foodgrade polymer.
• A common hopper is designed for both Rotary and Gravity feeder.

Front Control System

• Pre-Compression Pressure, Main Compression Pressure and Weight can be set using control knobs located on front panel.
• The control knobs are calibrated and fitted with dial indicators.
• All controls are connected using universal joints eliminating chain and sprocket mechanism.

Control Panel

• Control panel is completely separate from the main machine. This prevents powder contamination.
• All machine parameters are controlled through a PLC- Main Motor Speed- Feeder Speed- Hydraulic Pressure Setting- Lubrication System- Safety Interlock
• The PLC also stores and displays Pressure, Tablet count, Turret RPM, Motor Ampere Product recipe and Batchdata.

Since every punch tip is very precise and accurate, slight wear & tear can result in production of dull or collared tablet. And hence, polishing of punch cavity is an important exercise to ensure reliability of the tooling process. Our punch cavity polishing kit helps you in acquiring the original cavity finish of your punches.

Our kit contains different types of brushes for different cavities & different types of pastes for varied application.
Since polishing is done to revive the original cavity finish, extreme care should be taken while doing it. One should avoid excessive or wrong polishing. The four most common errors while punch cavity polishing are:

• 'Rounding' of the outside diameter of the tip
• 'Rounding' of the edges of the tip face
• 'Distortion' of embossed details
• 'Distortion' of the tip face

Normally a lot of dust is generated during the compression process. This dust if not controlled would settle in the upper punches, turret and other parts in the compression zone. Excess dust in the compression zone can lead to black particles, upper punch jamming and various other problems. It is therefore advisable to have a Dust Collector unit attached to the tablet press to suck out the dust generated.

On prolonged usage, punches & dies, are likely to give rise to the following problems:

• Excessive weight variation
• Tablet hardness variation
• Excessive powder seepage from lower punch or collar formation
• Bending of small size punch tips caused by excessive compression pressure

These problems need to be adhered to in due time to avoid excessive damage later on. Our inspection kit can be used to identify the inconsistencies in tooling. We can check the following parameters:

• Working height uniformity of all punches
• Punch tip & body diameter
• Punch tip to body concentricity
• Die OD & Height
• Die bore go / no-go status

For tablets that are small in size and are required to be manufactured in huge volumes, we provide multi-tip tooling. In these tooling more than one tip is accommodated on a single punch thereby increasing production substantially.
However using this tooling requires a lot of skill and does have shorter life than normal tooling. It is recommended ideally where the tablet size is very small, hence many tips can be accommodated which would help distribute the compression force over a larger area.

We also make De-dusters & Dust Collectors which have today become a necessity in most pharmaceutical companies. These not only improve the tablet quality but also increase production by ensuring trouble free production and allowing running of tablet presses at higher speeds.

De-DustersA de-duster ensures that the tablets produced are clean, do not have any loose particles and reach the consumers intact. It also removes burr on the edges thereby reducing packaging problems and improving the look of the tablet.We offer 2 types of de-dusters: Spiral Model and Vibratory Model.

Shaped toolings have a shorter life than round toolings. One of the major reasons is that the wear & tear of the underside of the punch head results in weight variation. To avoid this we have created a rotating head tooling so the punch head can rotate just like round tooling and avoid this wear and tear, thereby giving it longer life.

For tablets that are sticky in nature, a common problem is jamming of the lower punch. The main reason for this is sticking of powder on the wall of die bore resulting in jamming of the tip in the die bore. To reduce this problem we give a sharp undercut on the punch tip, acting like a scrapping blade, which cleans the die bore at every compression.

Sticking is a major problem faced while manufacturing effervescent tablets. Not only does the powder stick to the punch face but it also corrodes the tooling. To minimize these problems we use Teflon tip punches as Teflon is less prone to sticking and the disc can be replaced if damaged.

In cases when corrosive material is used or for very high volume products or products which require high compression force - the punches get corroded and a die ring is formed very fast. To avoid this wear and tear and to increase the life of the tools we use a very hard metal; Tungsten Carbide in the contact areas.

These are useful for products that require high surface area. Typically used for confectionery products. Also used for making Tablet-in-Tablet.