Tablet Machine: The Complete Buying Guide In 2024

How tablet machine significant?

In today’ blog post, you will be known about this robust and reliable machine which has wide and broad applications around the globe. Now you can enjoy making tablets of various shape, weights, sizes with professional results by using a tablet machine.

If you think, it will be an expensive machine or can not afford it. Then you might be wrong. Please read this blog and find out what’s more it offers you to with an astringent amount.

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1.What is tablet machine?

Allpack Tablet Machine

So basically, tablet machine is used to compress the granular or powdered material into tablets of different shapes and sizes to ensure uniform distribution of drug. That is why it is called as tablet machine or pill press. This machine is operated by series of steps such a powdered material is placed in die cavity, high pressures are applied and finally formed tablet is ejected.

Such machines are commonly used in pharmaceutical and other related industries, where precise dosing, large production of batch with consistency and accuracy are required. These are important as they benefit the quality production with improved shelf life and stability. This minimal variation of dosage and sizes also improves the patient compliance because of familiar medication administration.

2.What are advantages of tablet machine? Why it is Important?

Precision

Every tablet has an active ingredient which plays a vital role in achieving maximum therapeutic effect, so tablet machines ensure the precise and accurate dosing with desired potency.

Efficiency

The production of large amount of quality product with minimal manufacturing time, this throughput is essential to meet the demands of manufacturer.

Quality control

Quality Control- picture courtesy: aaps.ca

Tablet machine ensures the overall quality of product. Variability within batches is strictly controlled in terms of size, shape weight variation to meet quality standards.

Convenience

Convenient equipment

Tablet machine is preferred over many other equipment just because of convenient presses, and safe formation,

3.What Industrial applications tablet machine offering its customers?

Pharmaceutical industry

Pharma tablets-- picture courtesy: alten.pt

Tablet machine is the vital part of this industry as it helps to manufacture a vast of array of medications with precise dosing and potency meeting all regulatory requirements.

Nutraceutical industry

Vitamin supplements

A supplement such as dietary vitamins, minerals, herbal extracts and bioactive compounds lies in such category. Tablet machines make sure precise dosing to meet consumer and market demands.

Cosmetic Industry

Pressed powder- picture courtesy: beautymag

Compressed eyeshades pallets, blushes, foundation cakes are also produced by such machines. These machines ensures the consistent texture and colors of cosmetic formulation to meet consumer demand.

Confectionary Industry

Candy tablets

In this industry, these machine enables the uniform size and weight of confectionary products such as candies , mint lozenges to appeal consumers.

Chemical Industry

Chemical Tablets

Tablet machine is used to compressed active chemicals to solid tablet formulation. These tablets are used as catalyst, disinfectants or agrochemicals.

4.What is classification of tablet machine?

Tablet Machine- picture courtesy: Ricardo

Tablet machines are of various kinds and types , commonly they could be classified on following factors , operating principle, feature design , production capacity and limitation and their automation level.

Classification of Tablet Machine

Operating principle

Single punch Tablet machine

Allpack Single Punch Tablet Machine

These machines are suitable for low scale production or for laboratory use, as it uses only single punch to compress the granulated or powdered material into tablets.

Rotary Tablet machine

Allpack Rotary Punch Tablet Machine

These machines are very efficient are highly recommended for large scale production as it as multiple die cavities and punches arranged on a rotating turret. High pressures are applied to compress the powder into tablet. It basically has a platform to hold dies and punches for tablet formation. Therefore, we can classify tablet machines according to turret type either rotary turrets or oscillating turrets.

Production capacity

Small scale Tablet machine

Allpack Single Punch Tablet Machine

These machines are used for small to moderate level of production volume used mainly in laboratories or small pharmaceutical facilities.

Medium scale Tablet machine

Flower Basket Tablet Machine- Picture Courtesy: Aipak

These machines are used for larger to moderate production volumes but not suitable for industrial scale.

High speed tablet Machine

Aipak High speed tablet press

These machines are capable of producing thousands of tablets per minute, ideal for large pharmaceutical industries where bulk amount of tablet formation is required. In this type, following sub-types of tablet machine are categorized.

Compressed Biscuit Tablet Machine

Allpack compressed Biscuit Tablet Machine

This type of tablet machine is specifically dedicated to manufacturing civilians' and military hard food that stays longer and fresh. This machine is based on rotary working those compresses biscuits and is considered as a key element behind its working.

Effervescent High Speed Tablet Machine

Allpack Effervescent High Speed Tablet Machine

This is kind of double tablet press giving you high production of effervescent tablets with special carving shapes firmly pressed into circular shapes. This machine is capable of producing single, bi-layer or multi-layer tablets which has high demand in medicinal sectors.

Automation level

Manual Tablet machine

Manual Tablet Machine

Such machines are operated manually that means it require manual filling of die cavity with material to form a tablet.

Semi-Automatic Tablet Machine

Semi automatic tablet machine- picture courtesy: aipak

These machines are not fully automatic means it requires human intervention in feeding the die and ejecting a tablet.

Fully automatic Tablet Machine

Fully automatic Tablet Machine- Picture Courtesy: Aipak

These types of machines are fully automated, means minimal to no human intervention required in tablet formation processes. All the steps are done by machine itself.

5.What is machine structure of tablet machine?

Allpack tablet machine

Tablet machines comprise of various parts and each part has different function to perform, following are the details.

Stainless steel hopper

Stainless steel hopper is made up of alloy which is composed of iron, chromium and nickel. This stainless steel is commonly used in pharmaceutical and food processing because of its anti-corrosive and hygienic properties.

Transparent sheet

The transparent sheet made up of polycarbonate or acrylic is used as a protective layer and also provides visibility of the interior of machine and technically prevent from potential hazards.

Tablet machine turntable

Tablet machines have a rotating platform for processing or assembling which comprises of compartments or stations where multiple tasks takes place like filling, compression, ejection in tablet formation.

Press control frequency controller

This part of tablet machine is responsible for regulating the speed and frequency of Tablet machine. It uses variable frequency drive to adjust motor speed for allowing the adjustments to particular production rates.

Exhaust outlet

Every machine has an opening to get rid of excess air , dust or fumes generated during process of tablet formation. This vent keeps the environment safe and clean from air borne particles which could lead to contamination.

Adjustable filling mechanisms

In tablet machine you can adjust the amount of material filled in a die mold or cavity by adjustable filling mechanism. With this mechanism we can control the amount of active ingredient dispensed, fill depth capacity, adjustable auger speed so that one could attain the uniformity in weight and accuracy.

Emergency switch

To avoid potential hazard or unwanted injuries, there is a prominent button clearly labeled so that one could press to stop the machine is a safety device that when pressed will halts the device in emergency.

Electric switch

Electric switch is responsible for power supply to the machine, it has several buttons to turn on or off, adjust specific setting of machines and to activate certain functions.

6.What is the working of tablet machine?

The working of the tablet machine involves several steps which are explained below:

Filling

Filling

Filling- Picture courtesy: ipharmachine

Filling is the first step in which powdered or granulated material is filled into hopper. Hopper led the powder to flow in the feeding unit called as feeding frame. Then feeding frame evenly distribute powder into the die cavity.

Metering

metering

Second working step is metering also called as weighing or dosage, in which precise amount of powder id weighed and then lower punch moves upward to remove excess material.

Compression

Compression- Picture Courtesy: Fluidpack

Compression is the third step; force is applied to compress powder into tablet. Furthermore, this process involves two steps known as pre compression and main compression.

In pre compression stage the upper punch descends downward to compress powder slightly and remove air pockets.

In main compression stage both the punches are brought together with much higher force to compress the powder so that it would attain the shape of tablet.

Ejection

Ejection of multi-layer tablets

Ejection is the last step in which the upper punch moves upward. Lower punch following the upper punch will raise the ejection and the tablets are ejected from the die bore to the scrapper, therefore scrapper will move the formed tablets into the container.

7.What is tooling of tablet machine?

To ensure the uniformity in shape sizes weight there are set of components in Tablet machine which are commonly referred as tooling. The primary components of the tooling tablet machines are:

Punches

Punches of tablet machine

Punches are the solid metal rod with specific sizes or imprint on it and it is used to compress the powder to form a tablet. There are two types of punches upper punch and lower punch. Upper punches descend from the turret or cam to compress the powder while lower punch rise to eject the formed tablet.

Dies

Dies

Dies of Tablet Machine

Dies are the solid metal mold which defines the size and shape of the tablets. Dies are arranged in a circular pattern on a turret or a rotary stand on a single punch machine. Each die consists of a punch cavity the upper die compresses the powder while the lower die ejects the formed tablet.

Die table

Die Table

It is a platform where all the dies a mounted. It rotates so that it could adjust the beneath die and adjust the indexes to carry out compression and ejection.

Die locks

Die Lock

Die locks are the phenomena to secure the dies in place during compression. They prevent dies from shifting under high pressure. They also ensure the uniformity in tablet thickness and prevent the damage of tooling.

Cam tracks

Cam Track

These are the channels or the grooves in the Tablet machine which ensure the correct placement and movement of the dies and punches during compression and ejection in tablet formation. It also ensures the precise alignment of upper and lower dies and punches.

8.How to maintain a tablet machine?

Maintaining a tablet machine- Picture courtesy: scientist live

Daily inspections and regular tunes ups are primarily required for the maintenance of the machine. Waiting for malfunction or unwanted incidents may halt the manufacturing processes which may cause a loss to economy in both ways like not meeting up the consumer requirement plus the wearing and tearing of machine parts.

Therefore, good preventive measures should be taken, and main principles must be followed,

Excessive wear: when parts are not aligning correctly the will start to be wear off and damaged.
Erratic compression and inconsistent weight control: it’s also an indicator to check whether machine is working promptly according to intended guidelines.
Poor yield: utilization of damaged machine parts mostly results in extra unwanted loss.
Migration of product outside zone: this is an indication of poorly adjusted part or utilization of damaged parts or seals.
Weird noises: operators must be monitoring unwanted sound and noises or extra vibration which is sign of damaged parts or misaligned parts.
Each and every part should be inspected regularly, informal or casual inspection may help to get rid of the problems or the problems are caught early.

9.What type of tablets can be produced from tablet machine?

Tablets are readily available in variety of ranges which differ in sizes or shapes. Variable tablet types are as follows.

Single layer tablet: Single layer tablets are those which have single active pharmaceutical ingredient.

Bilayer tablets: bilayer tablets are made as the first layer with active ingredient is compressed and then other powdered material are kept on formed tablet and compressed together to form a bilayer tablet.

Multilayer tablet: multilayer tablet is those which comprises of more than two active ingredient, the purpose of this tablet is to pave off the effective drug delivery system

Effervescent tablet: effervescent tablets are carbon tablets normally larger than standard tablet and intended to dissolve in liquids.

Chewable Tablets: are those ingested upon chewing and obtain active compounds.

Laundry Tablets: are those used for laundry purposes that produce foaming effects when react with water and cleanse the sticky and hard stains.

Medicine Tablet: which is entirely made up of medicinal active pressed firmly by a tablet machine that exerts therapeutic effect upon ingestion.

10.What are the solutions and problems of tablet machines?

While working with tablet machine manufacturer must experiences some pitfalls but the expert is one who knows how to overcome the problem.

Capping of tablet after compression

Capping- Picture Courtesy: Sciendirect

This is because of the trapped air inside the die cavity and extra dry nature of the granulated or powdered material. This is overcome by increasing the dwell time of pre compression stage so the it will get extra time to come out. Make the use of enough lubricant for the compression of powder.

Lamination of tablets

Lamination- Picture Courtesy: Merlin Powder

Over compression or the inappropriate dies can cause the tablet to get cracked. So to avoid this one must enhance pre compression time to lead powders to stick together. To avoid lamination, tapered dies must be used.

Tablet particles stick to the punch or tip heads

Particles stick to the punch- Picture Courtesy: Pharm Tech

This is one of the major serious issues caused when particles from inside are wet , not dried completely tend to stick to punches. Sometime punching tools are also responsible for particles picking. Solution to such problem is increasing the pre compression dwell time for complete drying up of particles. After wet granulation particles must be given extra drying time. Regular polishing of pinches and dies will also reduce the tablets sticking to their heads.

Tablets binding happen inside the die restricting the way for tablet ejection

Tablet fails to ejects- Picture Courtesy: Tablet and capsule

When too much binding agent is used this leads the tablets to hold itself to die cavity and end result is a crumbled tablet when ejected. To avoid this problem binding and lubricating agent must be added carefully, and also makes sure that mixture is well dried.

Tablets friability

Tablet Friability- Picture Courtesy: Biogrund

When the granule with no fine powder is used, less binders are used, high compression speed is set, these all may encompasses the various problems of tablets in packaging, delivery, and coating. Solution to this problem is simple and easy, just use correct number of binders and maintain a suitable compression speed. Furthermore, also reduce the size of granules.

Conclusion

A tablet machine is mandatory not only for pharmaceuticals company but also for various field of manufacturing. Machine is offering promising production with even weight and sizes of tablets using correct and refined configurations to meet your expectations. When choosing a tablet machine, consider Allpack to get programmable equipment in a pocket friendly manner. Please contact us for more information & support.

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Coating Machine in Pharmaceutical Industry-1

Coating Machine in Pharmaceutical Industry: The Complete Buying Guide In 2024

Tablet Coater

Coating Machine in Pharmaceutical Industry: The Complete Buying Guide In 2024

Every pharmaceutical industry needs a solution to coat solid dosage formulation. Do you know the reason?

This is an important process step ensuring that tablet or capsule is meeting patient compliance in the term of masking taste and enhancing colors and other in-taking high demands.

With our vast experience on dealing coating machine in pharmaceutical industry; we have designed a combined effort and expertise to create the guide on ‘Coating Machine in Pharmaceutical Industry’.

Please read on to explore about this significant equipment.

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1.What Is Coating Machine In Pharmaceutical Industry?

Coating Machine In Pharmaceutical Industry- Picture Courtesy: Aipak

The coating machine in pharmaceutical industry is used to coat a dosage form i.e., granules, tablets, capsule with coating material which is either sugar or film solution over the outer surface to achieve certain required actions.

The machine is designed with simple to complex form, small to large in structure to bring an even distribution of coating material over coating bed. The machine is specifically used in pharmaceutical industry as to achieve desirable results upon reaction of drugs at a specific target site.

A coating machine in pharmaceutical industry is a simple to use machine with certain limitations that everyone must consider (discussed later part of the blog).

2.When Coating Machine In Pharmaceutical Industry Developed?

Concept of Coating Initiated in the Early 1800s

Initially, the concept of coating began with Rhazes using psyllium seeds to hinder its bitter taste. It was later reported by Avicenna.

In 1838, Garot used gelatin to coat pills. The poisonous tablets were specially coated to prevent unintentional consumption. In 1842, sugar coating was introduced, and in 1950, the sugar coating technique was considerably used with coating machine in pharmaceutical industry.

The same technique was employed in food industries to coat candies. Today sugar coating and film coating processes using coating machine in pharmaceutical industry are the most prevalent techniques across the globe.

3.Why Do You Need Coating Machine In Pharmaceutical Industry?

The pharmaceutical solid dosage formulations are susceptible to degradation by external environment factors. Therefore, you always need to coat them for extra protection. Besides this, the emergence of coating machine in pharmaceutical industry is always in demand due to the following reasons:

Improving Shelf Life

Coating machine in pharmaceutical industry extends drugs shelf life

Coating machine in pharmaceutical industry is used to extend and stabilize the shelf life of solid dosage form by forming a protecting layer against its interaction with external physical parameters like light, moisture, air, etc.,

Masking Bad Taste

No bitter taste with coating machine in pharmaceutical industry

Previously, it was a problem when taking solid dosage forms. In fact, for many patients, ingesting a tablet or capsule was intolerable due to its taste. A coating machine in pharmaceutical industry is high in demand due to masking the bad or bitter taste of medicines.

Masking Bad Odor

No bad odor

Many solid medicines are presented with bad odor, coating machine in pharmaceutical industry masks unbearable odor by firm coating over dosage form.

Smooth & Polished Appearance

Glossy appearance

You can enjoy the smooth shape and shiny/ glossy appearance of pharmaceutical solid dosage form with the dexterity of coating machine in pharmaceutical industry.

Dosage Identification

Better dose identification

By different coating color, marking, identification code helps in identifying the right dosage.

Patient Compliance

High Patient Compliance

The attractive appearance of medication directly encourages patients to accept medication of the prescribed regimen.

Control Release of Active Pharmaceutical Ingredients

Controlled release medications- Picture Courtesy: Kanjivaram

The coating machine in the pharmaceutical industry is used to manufacture dosage formulations based on various different sites of release, time of release, or target site release.

Protecting the Gastric Mucosal Layer

Safe Medication for patients- Picture Courtesy: The medicine Maker

Dosage form without coating can directly interfere with internal gastric mucosal and damage the inner lining causing pain and bleeding if medication is used for a longer time. That’s why coating machine in the pharmaceutical industry is used to minimize this flaw in dosage form.

4.What Is The Scope Of Coating Machine In Pharmaceutical Industry?

Apart from pharmaceuticals, a coating machine has a broad scope of applications in various other industries. Some of them are discussed below:

Industry	Description	Picture
Foods	The machine is frequently used in food industry for coating products such as chocolate, coffee beans, candies, nuts, and gummies. This is done to enhance appearance, texture and taste.
Automotive	To enhance protective coating of tools and parts of automotive components. A coating machine is utilized for improve corrosive resistant layer and extends the shelf life and durability of the parts of vehicles.
Fabric	Coating and coloring of dyes on textiles and material relevant to fabrics are done by coating machine.
Electronic	Electronic components, tools, switches, connectors, and other materials are coated using coating machine for enhancing appearance and make them more durable.
Chemical	Various chemical granules and tablets are coated by using coating machine.
Agriculture	The shiny glossy appearance of fertilizers, pesticides, insecticides, seeds, and relevant products is done by a coating machine.
Nutraceuticals	Multivitamins, capsules or tablet supplements, trace elements, minerals, proteins, enzymes, and probiotics in the form of solid dosage forms are usually presented with smooth textured and flavored coat. A coating machine is the robust machine that has widely applications in nutraceuticals.
Homeopathic & Herbal	Various granules, tablets, capsules are manufactured in this field are suggested to be coat to increase patient compliance and improved marketability. You can’t ignore coating machine while they are manufacturing.

5.What Are The Types Of Coating Machine In Pharmaceutical Industry?

There are many types of coating machine in pharmaceutical industry.
For example,

Standard Coating Machine in Pharmaceutical Industry

You can also call it a conventional or traditional coating pan which was commonly used in pharmaceutical industries for the coating of dosage forms.

This machine is designed in a manner where a rotary circular pan which is also known as a drum is responsible for coating of dosage form.

An ideal diameter of a coating drum is about 6–80 inches which is commonly titled at the angle of 45 degrees.

An electric motor which is fitted horizontally inside the drum causing tumbling of coating bed.

The standard coating machine in pharmaceutical industry is further classified into the following:

Pellegrini/ Baffled Diffuser Pan

Pellegrini Coating Machine- Picture Courtesy: Aron

A standard pan with added Pellegrini baffled diffuser to improve drying and tumbling of coating by even distribution of warm and hot air.

The tablet bed was successfully achieved with an even distribution of material by drying air over entire material.

Immersion Sword

Allpack Immersion Sword Coating Machine

As the name indicates, a long sword like spray nozzle is subjected to deliver a hot air over the tablet bed.

This process is ideal for getting high drying from apparatus. This coating is relatively offering high speed coating due to the circulation of airflow in the middle of the coating bed because a sword is embedded in the coating material.

Immersion Tube System

Immersion Tube System- Picture Courtesy: ipharm

This type is accompanied by another additional tube in the coating bed with provides coating solution and dry hot air simultaneously.

The design of the machine is done in such as manner where heated air leaves the solution an upward direction. The drying and efficiency of machine is more enhanced than conventional pan simply by inclusion of an immersion tube.

Perforated Coating Machine in Pharmaceutical Industry

Perforated coating machine in pharmaceutical industry- Picture Courtesy: Freund Vector

This technique is widely accepted by pharmaceuticals industries which is composed of full, partial perforated coating drum. Likewise, standard coating pan, this machine is also composed of rotating drum with horizontal axis and is equipped with an atomizer spray with an airflow inlet at the top of the pan.

Due to high air flow pockets, and high capability to deal tablets for coating, this machine is more promising than other coating machines.

There are three designs of perforated coating pans in pharmaceutical industry:

AccelaCota System

AccelaCota System

This is a fully perforated pan where the hot blowing of air is passed from upward direction which goes downward over coating bed and the exhausted air leaves the unit from bottom by plenum. The baffle in the rotary drum is responsible for complete tumbling of dosage form to ensure free mixing of coating and effective drying.

Dria Coater Pan

Dria Coater Pan

The coating pan is accompanied by perforated ribs featured on the inner periphery of the drum. In this machine, the basic working is like accelacota , but hot air flow from downward to upward direction. The exhausted air is flowed at the back of the machine and eventually leave the unit.

Fluidized Bed Coating Machine in Pharmaceutical Industry

Fluidized Bed Coating Machine- Picture Courtesy: Abbot mitre

This machine is responsible for the fluidization of coating particles. It follows the fluidization working principle with an increased air concentration that enters the column and raises the tablets or capsule or any material in the air to carrying out coating procedure.

The machine has a vertical cylinder where dosage form is suspended and spray nozzles that sprays the coating material. The materials are dried via an upthrust of hot air. The fluidization phenomenon occur which causes dosage form to move upward and downward.

Coating machine in pharmaceutical industry Based on Pressure

On the basis of pressure system, the coating machine in pharmaceutical industry is categorized into two types:

High-Pressure Airless System

High-Pressure Airless System

This machine pump out coating solution without need of air, means the coating solution is sprayed out using a very high pressure which is up to 250,300 psig. The machine is featured with small nozzle about 0.0090 to 02 inches.

The size of the orifice and fluid pressure is regulating the rate of atomization and spray.

Low-Pressure Air-Atomized System

Low-Pressure Air-Atomized System

This unit utilizes a low pressure of 550 psig via a 0.020-inch larger orifice. The fluid cap orifice, air pressure, and air cap are responsible for modulating spray rate and atomization.

6.What are the Major Parts of Coating Machine in Pharmaceutical Industry?

Allpack Coating Machine In Pharmaceutical Industry

Exhaust Blower

The exhaust blower is responsible for eliminating humidity or moisture content generated during coating process.

Coating Pan

The coating pan is used to adjust the coating bed and rotating continuously for even coating of solution over coating bed.

Inside Mixing Baffle

This is presented inside the coating drum or coating pan for uniform mixing and even blowing of air for equal distribution of coating solution.

Solution Tank

The coating solution is stored in a solution tank which is sprayed over the coating bed using spray nozzle. This tank is responsible for maintaining the complete and uninterrupted flow of solution.

Control Panel

The operating keys, and protocol parameters, for example, rate of rotation, rate of spray, temperature modulation, and other variables are controlled by a control panel.

Cooling Unit

This unit allows a controlled flow of air to cool down the inside temperature required for coated material.

7.What are the major Process steps of Coating Machine in Pharmaceutical Industry?

The working steps of coating machine in pharmaceutical industry are described below:

STEP 1: Preparation

Preparation

The preparation involved with the formulation of coating and identification of the batch. This is an essential step where the overall result is based, it will assure consistency in throughput.

STEP 2: Loading

Loading of Dosage formulation inside coating machine

Loading of subjected dosage formulation is loaded into the coating machine by the help of manual handling or machine hopper. This is a subtle process where smooth loading of dosage form takes place to avoid damage to surfaces.

STEP 3: Heating

Heating

Heating

Application

Temperature

°C

°F

122

Heating

This step is carried out to minimize the moisture inside the drum and make the coating bed warm up to the required temperatures. Now your product is ready to coat.

STEP 4: Spraying

Coating Spraying- Picture Courtesy: Spraying System

Application	Temperature
Application	°C	°F
Tablet Coating	70 – 90	158 – 194

After warming, atomization is carried out by the help of a spray gun over the coating bed. The solution is sprayed using a peristaltic pump set inside the spray gun offering a finest layer of coating solution with uniform distribution of spray particles over each part of the object.

STEP 5: Drying

Drying

Drying- Picture Courtesy: Syntegon

Application	Temperature
Application	°C	°F
Drying	40 – 60	158 – 194

Heat drying is carried out to evaporate solvent molecules presented in the coated solution and dries the surface. In a result, you can get a smooth coating.

STEP 6: Repetition

Repetition- Picture Courtesy: Fluid Handling Pro

Now, once again spraying and drying procedure is repeated to get the optimum thickness of coating bed.

STEP 7: Cooling

Cooling

Cooling

Application	Temperature
Cooling	Typically Room Temperature

Once you achieved the desirable coating, stop the process and allow the coating bed to cool down via continuous rotation of coating drum. This is done to prevent clumping between coating particles.

STEP 8: Discharging

Discharging- Picture Courtesy: TabletCapsule

After the procedure, the coated dosage formulation is discharged from the coating machine manually or by conveyor unit.

8.How Coating Machine In Pharmaceutical Industry Impacts On Release Of Dosage?

A coating machine in pharmaceutical industry has a great impact on releasing action of different solid dosage form by affecting profile, bioavailability, target site of action. There are certain specialized and commonly used solid dosage forms with variant delivery times and sites.

Sustained Release (SR)

Sustained Release (SR)- Picture Courtesy:Unguent

The name tells everything, it releases drugs in an extended time and coating is applied to design formulation that can maintain the action of active ingredients in the bloodstream. The coating machine in pharmaceutical industry is used to make drug with modified release kinetics and offering a steady and sustain releasing with time.

Enteric Coatings

Enteric Coated Tablet- Picture Courtesy: Formasup

Enteric word is commonly used for intestine. There are many drugs that can destroyed by the action of stomach enzymes. Therefore, coating machine in pharmaceutical industry is used to prevent the degradation of drugs by forming a coat which resists gastric enzymes and release drug safely in the intestine as it dissolves in an alkaline pH.

Immediate Release (IR) Formulations

IR formulation- Picture Courtesy: Pharma Excipient

A coating machine in pharmaceutical industry is beneficial to manufacture drug that offers an immediate releasing action once it reaches to target site and protects its from environmental factors like light, moisture, etc.,

Targeted Drug Delivery

Targeted Release Tablet- Picture Courtesy: Forbes

To achieve target drug delivery, a coating machine in pharmaceutical industry is used to engineer specialized coating in order to get a targeted drug delivery at a specified site of action. For example, inflamed cells, brain cells, cancerous cells etc., This is required as the minimum drug can specifically reaches and offering maximum efficacy.

Extended Release

Extended-Release Medicines- Picture Courtesy: Novant Health

To release a longer duration of action and high effectivity, an extended-release drugs are formulated. For that, coating machine in pharmaceutical industry use various specific polymer matrices that are designed to diffused with drugs and ensure extended releases.

9.What Polymers Used For Coating Machine In Pharmaceutical Industry?

Polymeric Formulation Used In Coating Machine In Pharmaceutical Industry

For coating of drugs, different combinations of polymers are used to alter the drug delivery and modify the action time and specific sites. The polymers with purposes are mentioned below:

Polymer	Purpose
Ethyl Cellulose	Offering Sustained release
Eudragit RS 30 D (alone and in combination with ammonia methacrylate)	Offering Sustained release
Kollicoat SR 30 D	Offering Sustained release
HPMC acetate succinate	Offering Enteric coating
Cellulose acetate phthalate (CAP)	Offering Enteric coating
Eudragit L 30 D 55	Offering Enteric coating
Eudragit FS 30 D	Offering Enteric coating
Chitosan	Offering Coating
EC, Shellac, Cellulose Acetate Trimellate	Used for Film Coating

Classification Courtesy: National Library of Medicine

10.What Factors Affect the Quality Of Products Using Coating Machine In Pharmaceutical Industry?

There are certain factors that can affect the overall quality of a drug, therefore when using a coating machine in pharmaceutical industry you must avoid those parameters. For example:

Coating machine in pharmaceutical industry- Picture Courtesy: L.B Bohle

Drying Procedure	This is pretty sure that efficacy and effectivity of coated drug can be affected if its coating is not dried sufficiently. Because an inadequate and uneven coating surfaces can progress the defects and batch failure.
Viscosity of liquid	Every liquid used in coating has various concentrations of viscosity. It affects the coalescence of the droplet during coating process. Knowing and managing the viscosities of coating liquid is helpful in obtaining an even coating when using a coating machine in pharmaceutical industry.
Uniform distribution of coating Particles	It is essential to maintain a consistent quality by considering surface tensions, wetting properties, and spreading action of coating to achieve an even thickness of coating.
Process Parameters	The distance between coating bed and nozzle, rate of coating spray, temperature, drying time, flow of air, have high impact on coating of drug. Therefore, it is essential to not ignore for desirable characteristic of drug.
Coating Material Quality	The composition of coating is very important which includes rheological properties, particle sizes, molecular bonding, that cumulatively impacts on coating of drug.
Equipment Features	The features of coating pan, spraying properties, and its maintenance can overall impacts on the coating properties of drug. The regular cleaning and calibration of the machine ensures a promising outcome of substrate.

11.What Is the Commonly Used Coat Of Coating Machine In Pharmaceutical Industry?

There are various types of coating solutions that are coated over oral solid dosage forms offer significantly improved properties to medicines and patient compliance.

When it comes to patient compliance and demand, there are various coating compositions that are used in coating machine in the pharmaceutical industry. They include:

Sugar Coating

Sugar coating

Do you love ingesting medicines from a pharmacy that tastes sweet? No doubt, after few minutes, you possibly feel some bitterness.

This is the reason; a sugar coating is done for easy gulping of medicines to enhance sweetness and mask bitterness of solid dosage form. This coating formulation needs skilled manipulation which mostly requires 3 to 5 days and involves application of sugar molecules such as glucose, sucrose, based solution within coating machine in the pharmaceutical industry.

This includes sub -sealing, sub-coating, smoothing, coloring, polishing, and final printing.

Film Coating

Film coating

A film coating is a procedure where a thin polymeric layer is coated over drugs which ranges from 20 and 100 µm to oral solid dosage form to alter its releasing properties that we already discussed above. This is a one-step coating process with a fast application as compared to sugar coating with a lesser margin in weight increase.

The components used in film coating are polymers, plasticizers, opacifiers, and vehicles.

Compression Coating

Compressed coating- picture Courtesy : pharma specialist

This is similar to sugar and film coating where core or already coated tablets are compressed with excipients to protect drug against environmental conditions.

12.How To Clean and Maintain A Coating Machine In Pharmaceutical Industry?

As coating solutions are frequently used in coating machine in the pharmaceutical industry; you will have to frequently clean and maintain the machine to extend its quality life and quality of coating process.

Conventional Method

Conventional method

As polymeric solution and sugar solutions cleans easily. Thus, it is difficult to picked or identify left over inside the coating machine initially. Therefore, one time cleaning with water is not sufficient.

The cleaning process mostly involves two-step washing with high alkaline detergent to clean polymers and acidic detergents to clear insoluble particles stick inside the pan and circulatory pipes. In the larger equipment, manual scrubbing is also done to eliminate pigments.

WIP & CIP Method

WIP and CIP Cleaning- picture Courtesy: Tabletcapsule

For equipment designs like fluidized bed coating machine, the regular cleaning after every batch is mandatory which is occurred by Wash in Place and Cleaning in Place methods. WIP method is partially automatic where you need to open some parts of the machine for cleaning, whereas CIP automatically cleanses inner parts of the machine with opening via high flow of hot water and air to ensure greater cleaning results.

13.What Are the Flaws Of Coating Machine In Pharmaceutical Industry? How To Solve Them?

Blistering

Flaw	Definition	Possible Reason	Treatment
Blistering	When coating over the surface of solid dosage form detaches or swelled, it forms a blister.	The common reason of coating blistering is high heat, entrapment of the gases during coating, high air spray	The condition could be treated with proper designing of protocol, using machine setting that offer mild drying, modulate air temperature.

Chipping- Picture Courtesy: Colorcon

Flaw

Definition

Possible Reason

Treatment

Chipping

In this condition, the coating over the surface of the dosage formulation become dented, cracked, chipped, or broken into around the edges to form a sub-standard shape.

When a coating machine in pharmaceutical industry coats with slow speed of rotation or slow flow of fluidized air in coating pan, it results in chipping.

You must be very careful during pre-heating, regulate the coating speed, and do not let over-dry the coating bed. It is helpful to encourage minimizing chipping problems.

Picking

Picking

Picking- Picture Courtesy: Colorcon

Flaw

Definition

Possible Reason

Treatment

Picking/ Sticking/ Adhering

This is a common problem where coating on the solid dosage form are adhere and may broke or erupted.

The possible reason of picking of tablets or capsule is due to the wet coating or insufficient air drying.

When coating machine in pharmaceutical industry dealt with an optimized condition such as reduced volume of coating solution, modulated temperature, and corrected air drying time; the picking can be overcome.

Tablet to Tablet color variation- Picture Courtesy: Colorcon

Flaw	Definition	Possible Reason	Treatment
Variation in coating appearance	The coating surrounding solid dosage form are uneven appearance and showing color defects.	This is due to improper dispersion of coating solution and variation in spraying.	For this, reform the coating solution, use proper concentration of plasticizer, polymers, and associated additives. Use correct size particles and proper distance between coating bed and nozzle.

14.What Are Essential Parameters You Must Know For Coating Machine In Pharmaceutical Industry?

There are certain factors that must be considered during the usage of coating machine in pharmaceutical industry to ensure batch to batch quality and a consistent output.

Inlet Air Temperature and Relative Humidity

Temperature and Relative Humidity

This is well known that’s inlet air temperature should be enough to evaporate solvents quickly to make the coating evenly dry. Similarly, if moisture content or amount of moisture is present in the air can affect the drying process which causes the sticking of tablets or capsules. Whereas too low humidity causes cracking or peeling. Therefore, relative humidity must be optimized.

Formulation of Coating Solution

Formulation Design

The design of the coating solution is a mixture of syrups, polymers, plasticizers, etc., each component must be properly added and carefully controlled to be compatible with the tablet and coating machine.

Spray Rate

Coating spray rate

If the rate of spray is low, there’s less coating or thin coating applied over the coating bed. While too high a rate can also result in thick layer. Both are unfavorable which results in sticking or capping.

Spray Distance

Spray Distance

Determine the distance between the spray gun and the coating bed and the distance between spray guns, must be adjusted to ensure the coating solution adequately reaches without causing pooling.

Pan Speed

A coating machine in pharmaceutical industry- Picture courtesy: European pharma

If the rate of pan rotation is too high or too low can result in defects like mottling, streak formation, or uniform coating. A high pan speed causes a thin coating while low speed results in the thickness of the coating.

Conclusion

Oral solid dosage forms (OSD) activity becomes more enhanced with coating applications. That’s why coating machine in pharmaceutical industry is hooked to great value and supports countless benefits. Today, Allpack as an expert supports major industry players across the globe and shares rich expertise related to coating machines and their applications on OSD. With Allpack, you can enjoy the complete range of coating machines to scale up your production facility. Our team is ready to serve you.

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Plastic Tube Sealing Machine: The Complete Buying Guide In 2024

Tube Filling Machine

Plastic Tube Sealing Machine: The Complete Buying Guide In 2024

Sealing tubes is not just science but also an art. The sealing of tubes required careful adjustment of seal parameters which is achieved by the plastic tube sealing machine. It creates strong and aesthetically pleasing tube seals that promote the marketability of products.

The plastic tube sealing machine is the master of precision and accuracy. No product recall and substandard seals are possible with a plastic tube sealing machine. It generates optimized results that bring huge profits for businesses.

Are you looking for the highest quality yet cost-effective plastic tube sealing machine? Then first, carefully go through this guide to acquire knowledge about certain facts about the plastic tube sealing machine.

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1.What is a Plastic Tube Sealing Machine?

Allpack Plastic Tube Sealing Machine

A plastic tube sealing machine is a type of packaging equipment that is used for tightly sealing and securing plastic tubes. It dose up different product materials inside the squeezable tubes and seals its opening to prevent product leakage.

By sealing tubes, this machine assures superior product quality. It fuses the plastic layers to ensure that the inner content of the tubes remains intact. Plastic tube sealing machine seals products in such a way that it promotes anti-counterfeiting and anti-tampering efforts. This equipment is useful for packing a broad variety of products like creams, gels, pastes, ointments, glues, etc in the tubes.

2.Why Plastic Tube Sealing Machine is Significant in Industries?

Plastic tube sealing is significant in industries because it is more advantageous in every aspect than hand-filling. It brings profitability and success to businesses. It is the perfect solution to all problems that arise with hand filling. Here is a list of benefits of the plastic tube sealing machine.

Fill Precision

Fill Precision of Plastic Tube Sealing Machine- Picture Courtesy: JDA Progress

One of the top advantages of a plastic tube sealing machine is its fill precision. Filling by hand is filled with filling and sealing errors. This results in precious product loss and product recall if the product is underfilled. However, the plastic tube sealing machine has automated filling systems that allow it to attain filling precision in every batch.

Versatility For Processing

Versatility For Processing by Plastic Tube Sealing Machine

With its simple and fast change of parts, this machine can easily carry out the job of filling tubes of diverse shapes and sizes. It is a versatile and flexible machine suitable for industries, filling different volumes of products and sealing different shaped tubes.

User-Friendly Controls

User-friendly Controls of Plastic Tube Sealing Machine- Picture Courtesy: PKN Packaging News

The plastic tube sealing machine has integrated user-friendly controls like an HMI touch screen by which users can swiftly program and set inputs like fill volume, seal pressure, seal temperature, and speed of the turntable. Pre-saved data recipes allow users to change format with just one click of a finger.

High Speed

High Speed Plastic Tube Sealing Machine

One of the biggest advantages of utilizing a plastic tube sealing machine in production is its high speed. It operates at extremely high speeds, thereby, filling and sealing numerous plastic tubes in one setting. High speed means high production efficiency, this in turn translates to more profits.

Hygienic Design

Hygienic Design of Plastic Tube Sealing Machine

The plastic tube sealing machine has a sanitary hygienic design, meaning it is constructed with top-quality materials that are easily cleaned. Due to its clean design, this machine has zero chance of product contamination. Hence, it abides by different safe and hygienic industrial standards making it the favorite of numerous manufacturers.

High Shelf Life

High Shelf Life

A plastic tube sealing machine as the name indicates, is used to seal the plastic tubes. This sealing increases the shelf-life of the products by completely enclosing them, which not only prevents their leakage but also keeps them safe

3.What are the Kinds of the Plastic Tube Sealing Machine?

Plastic Tube Sealing Machine Types

There are different kinds of plastic tube sealing machines in the market. These machines create huge confusion when making a selection. Hence, we are detailing different kinds of plastic tube sealing machines so you will choose the right machine type.

According to Automation

Manual Plastic Tube Sealing Machine

Manual Plastic Tube Sealing Machine

It is a small compact unit, consisting of handles and a lever for plastic tube sealing. This type of plastic tube sealing is one of the simplest tube sealing units, having a smaller price bag. This machine requires labor for loading and unloading the plastic tubes. It seals one tube in one go. A manual plastic tube sealing machine is easily accommodated on desktops.

Semi-automatic Plastic Tube Sealing Machine

Allpack Semi-automatic Plastic Tube Sealing Machine

It is a compact unit with a smaller footprint than an automatic plastic tube sealing machine. It has more productivity than a manual plastic tube sealing machine. This machine is seen in medium-sized productions. It comes with HMI so program options are easily adjusted without the need for high training. This machine is labor-intensive, as operators have to carry out the job of loading and unloading tubes.

Automatic Plastic Tube Sealing Machine

Allpack Automatic Plastic Tube Sealing Machine

It is a larger-sized machine, that automatically carries out the loading, unloading, filling, and sealing of the plastic tubes. Although it is a costly option, it has more productivity because of its automated and high-tech controls. It is a perfect solution for larger productions as it has a minimal rate of error in filling and sealing.

According to the Sealing Pattern

Standard Seal Plastic Tube Sealing Machine

Allpack Standard Seal Plastic Tube Sealing Machine

This type of plastic tube sealing machine creates a standard type of seal having straight-line designs. Standard seal plastic tube sealing machine forms seals with straight distinct corners.

Curved Seal Plastic Tube Sealing Machine

Curved Seal Plastic Tube Sealing Machine

This machine joins the plastic edges in such a way that curve seals are formed. This machine creates a curved arc-type seal. The corners of these seals are round, so preventing the risk of cutting, which is possible with sharp corners of tubes.

Round Corner Seal Plastic Tube Sealing Machine

Round Corner Seal Plastic Tube Sealing Machine

It creates seals in such a way that they resemble an oblong shape with round corners. It creates straight-line seals with round-shaped edges.

Custom-Seal Plastic Tube Sealing Machine

Custom-Seal Plastic Tube Sealing Machine

This machine is customized to create unique shape seals like half curves or seals with euro slots. This type of plastic tube sealing machine is mostly used in the cosmetic industry to boost the presentation and marketability of cosmetic tubes.

According to the Sealing Method

Hot Air Plastic Tube Sealing Machine

Hot Air Plastic Tube Sealing Machine

This machine uses hot air for sealing plastic tubes. It is a quick and versatile machine handling a variety of plastic tubes. Hot air in this machine increases the temperature of the plastic tube to make it ductile and cold sealing jaws using chilled water closes the ends shut. However, it requires more changes of parts for handling different-sized tubes.

Ultrasonic Plastic Tube Sealing Machine

Ultrasonic Plastic Tube Sealing Machine

This type of plastic tube sealing machine uses high-frequency ultrasonic vibration to hermetically seal and fuse tube ends. The vibrations lead to the heating and melting of the seal end. The plastic tubes are passed between the sealing horn and anvil that maintain and form the seal. This machine has slower productivity than a hot air plastic tube sealing machine. But it needs lesser replacement of parts when processing different-sized tubes.

Hot Jaw Plastic Tube Sealing Machine

Hot Jaw Plastic Tube Sealing Machine

This machine uses high pressure and temperature to crimp seal the exterior of the tube. High temperature at the exterior side transfers to the inner tube ends and hot jaws or crimp jaws exert pressure to shut the tubes. This machine requires more time for sealing the tube and has lower efficiency than other methods.

Induction Seal Plastic Tube Sealing Machine

Induction Seal Plastic Tube Sealing Machine

This machine uses a high-frequency electromagnetic field to heat and melts the aluminum or plastic materials and then seal the lids or ends of the plastic tube. This machine creates tamper-evident strong seals. It creates clean seals without burning the material which is possible when using a hot air plastic tube sealing machine.

Metal Seal Plastic Tube Sealing Machine

Metal Seal Plastic Tube Sealing Machine

This type of plastic tube sealing machine is used to flatten and crimp seal the metal tubes. This machine creates different kinds of sealing like single fold, double fold, saddle fold, and triple fold to form sealing of metal tubes.

4.What is the Structural Design of Plastic Tube Sealing Machine?

Different parts that are featured in the plastic tube sealing machine are penned below:

Parts of Plastic Tube Sealing Machine

Product Hopper	It is a conical shape component that is typically featured at the upper side of the plastic tube sealing machine. Its main task is to hold the product for continuous running operation.
Tube Sealing Station	It is the part of the machine that uses ultrasonic vibrations, electromagnetic current, and heat to melt and seal the layers of the tube.
Tube Feeder	It is a rectangular-shaped device found on the upper side of the machine. It is used to store numerous tubes. It loads tubes one by one in the tube holder.
Tube Outlet	It is an elongated chute-like device in which tubes are ejected after completing filling and sealing.
Tube Holder	It is a hollow cavity that resembles a pocket in which tubes are placed for secure filling and sealing. It prevents the falling of the tube and keeps them in place.
Caster	It is a stand-like structure that holds the full weight of the machine. It stabilizes the machine and keeps it leveled.
Alarm System	It is a safety component that flashes lights and creates sound to inform operators about the problems of the machine like tube jamming, low tube numbers in the tube holders, etc.
HMI	It is an interactive display screen that is used for swift and convenient programming of the machine operation.
Filling Nozzle	It is a cylindrical tube pipe-like device, whose main job is to dose the product inside the tube. It is connected to the hopper by the hose pipes. For drip-free dispensing of the products, the filling nozzles are elongated to reach the bottom of the tube.

5.What is the Working of a Plastic Tube Sealing Machine?

The working steps of a plastic tube sealing machine are simple and act in synchronicity to perform flawless tube filling and sealing. Here is a list of steps that are executed in working of plastic tube sealing machine.

Plastic Tube Loading

First, the empty tubes are placed in the tube feeder. This tube feeder is high and automatically loads the empty tubes in the tube holder using a high-quality mark sensor. This mark sensor detects the marking present on the tubes and places the tubes in the right orientation based on their marking.

Plastic Tube Loading- Picture Courtesy: Norden Machinery AB

Plastic Tube Filling

Immediately upon the detection of the tube under the filling nozzle, the product dispensing starts under the direction of the signaling by the PLC system.

Plastic Tube Filling- Picture Courtesy: Makwell

Plastic Tube Sealing

In the next step, high heat from hot air melts the seal ends of the tube. These melted ends are joined using pressure provided by the sealing jaws. It creates strong hermetic sealing. The cooled water is employed at the same time to provide the seal ends with a smooth finish.

Plastic Tube Sealing

Plastic Tube Trimming

At this station, excess tube material is cut by the high-shear cutting blades. Some kinds of plastic tube sealing machines employ laser for cutting the edges of plastic tubes. The laser precisely and smoothly cuts the tube ends.

Plastic Tube Trimming

Plastic Tube Ejection

Finally, filled and sealed tubes are unloaded from the machine using a small outlet or a chute.

Plastic Tube Ejection

6.What are the Industrial Uses of the Plastic Tube Sealing Machine?

A plastic tube sealing machine is an efficient, quick, adaptable, and robust unit. It is used in various industries for filling and sealing different kinds of consumable items in sturdy tubes. Some of the basic industrial uses of the plastic tube sealing machine is discussed below:

Cosmetic Industry

Use of Plastic Tube Sealing Machine in Cosmetic Industry

Looks and product presentations are two things that play a significant role in the cosmetic industry, so this industry employs a plastic tube sealing machine because it improves the visual appeal of numerous cosmetic products, for instance, foundation, mascara, face wash, blushes, dyes, mask, lip gloss, sunscreen, serum, etc.

Personal Care Industry

Use of Plastic Tube Sealing Machine in Personal Care Industry

Plastic tube sealing machine is a prime part of the personal care industry because several personal care products like toothpaste, gels, shampoo, body wash, soaps, conditioners, and many more are available in the tube format. This machine is used for securely sealing such products in durable plastic tubes.

Pharmaceutical Industry

Use of Plastic Tube Sealing Machine in Pharmaceutical Industry

In the pharmaceutical industry, this machine is utilized for safely and hygienically packing different kinds of pharmaceutical creams, gels, ointment, burn salves, analgesics, dermal lotions, eye drops, and medicated adhesives. This machine with its sanitary design is involved in contamination-free packaging and sealing of pharmaceutical products.

Food and Beverage Industry

Use of Plastic Tube Sealing Machine in Food Industry- Picture Courtesy: News| Norden

Different food items require hygienic loading inside the tubes and that is where a plastic tube sealing machine plays a chief role. It seals food products like condiments, pastes, oils, ketchup, sauces, dressings, spreads, and jams in secure squeezable plastic tubes.

Chemical Industry

Use of Plastic Tube Sealing Machine in Chemical Industry- Picture Courtesy: Envato Elements

Different chemicals like sealants, adhesives, caulks, grease, inks, lubricants, and fuel oil require robust packaging that is leak-proof. Hence, these chemicals are securely packed inside the tough plastic tubes by the plastic tube sealing machine. These tubes are airtightly and completely sealed by this machine to prevent leakage of damaging chemicals.

Paint Industry

Use of Plastic Tube Sealing Machine in Paint Industry

Yes, a plastic tube sealing machine is also employed in the paint and coating industry to seal the oil and water-based paints inside the vibrant and colorful paint tubes. This machine also packs different kinds of coating and oily emulsion in the plastic tubes.

7.What is the Sealing Temperature of a Plastic Tube Sealing Machine?

Sealing Temperature of Plastic Tube Sealing Machine- Picture Courtesy: Makewell

The sealing temperature is dependent upon various factors like the nature of the plastic material, for example, PE plastic needs a low sealing temperature of about 250°F - 350°F for sealing while PP plastic requires a high temperature of 300°F - 400°F for bonding.

In a hot jaw plastic tube sealing machine materials are directly heated, so a high temperature of about 200-500°F is used for sealing. In induction seal plastic tube sealing machine materials are indirectly heated by electromagnetic induction, so a temperature of 150°F - 250°F for bonding the plastic material.

8.What is the Dwell Time of Plastic Tube Sealing Machine?

Tube Sealing- Picture Courtesy: The Tube Council

The dwell time of the plastic tube sealing machine means the duration in which hot air, heated jaws, or ultrasonic waves remain in contact with the plastic tube. It is the time amount during which temperature and pressure are applied to the plastic tube for sealing.

Proper duration of dwell time is very critical in the correct melting and bonding of plastic tubes. It is necessary for forming an operative seal. Inadequate dwell time for sealing results in weak and poor seals that may cause products to leak from the plastic tubes while high dwell time may result in the burning of tube materials.

Hence, it is an essential parameter for plastic tube sealing, influencing the quality and efficacy of the seal.

9.What are Other Materials Processed by Plastic Tube Sealing Machine Beside Plastic?

The plastic tube sealing machine can handle a broad range of materials besides plastic. Here is a breakdown of some common materials handled by a plastic tube sealing machine.

Aluminum Laminate

Allpack Aluminum Laminate Plastic Tube Sealing Machine

It is created by layers of plastic and aluminum. It combines properties of both aluminum and plastics like toughness, durability, and, ductility. These aluminum laminate tubes are used in the food and pharmaceutical industry for the packaging of gels and pastes.

Composite Paper

Composite Paper Tubes- Picture Courtesy: TOPPAN

These are formed with plastic and paper layers. It is ductile and strong like plastic and has a smooth finish of the paper. These tubes are gaining traction because they are easily recyclable and offer sustainability.

Aluminum

Aluminum Tubes

These materials are processed by the plastic tube sealing machine in the cosmetic and personal care industry. Aluminum imparts these tubes a premium and luxurious look and attracts high-end users.

10.How To Maintain Plastic Tube Sealing Machine?

Maintenance of Plastic Tube Sealing Machine

Adherence to a regular maintenance schedule of the plastic tube sealing machine brings many fruitful results, like optimal machine performance and long operational life. These are some tips to keep your equipment in top condition.

Cleaning Regularly	Clean thoroughly the exterior, frame, sealing area, filling nozzles, etc with a clean cloth and mild cleaning agent to remove the product and plastic tube material buildup that decreases sealing efficiency.
Calibration	Check and calibrate the sensors, heating elements, and pressure gauge.
Alignment	Align and level filling and sealing components to ensure they are properly positioned on the plastic sealing tubes.
Lubrication	Lubricate all the mobile joints and moving parts of the machine to prevent frictional buildup and overheating of the plastic tube sealing machine.
Full Examination	Examine all the machine parts like electric components, safety alarms, and pneumatic systems thoroughly for wear and tear and replace them if needed.
Software Update	Check and update the software of the machine if available.

11.What are the Common Challenges of Sealing in the Plastic Tube Sealing Machine? How to Overcome Them?

The plastic tube sealing machine can face some unanticipated challenges that may result in loss of productivity and packaging. Here is a list of common challenges encountered by the plastic tube sealing machine.

Challenges in Heat Sealing

Challenges in Heat Sealing

When the machine is started for the day, sealing jaws takes more time to heat and melt the plastic tubes. Also, these sealing jaws remain heated after the machine shuts down, making it difficult to clean the machine. Products like salads, spreads, etc also leak from the tubes because of the heating process.

Solution

These challenges can be overcome by the ultrasonic seal plastic tube sealing machine. It easily seals the plastic tube at the molecular level using an ultrasonic seal horn. It quickly seals products without any leakage. Moreover, it is easier to clean this type of plastic tube sealing machine.

Plastic Tube Material Stick to Sealing Jaws

Plastic Tube Material Stick to Sealing Jaws

Sometimes, the tube material adheres to the sealing jaws even after lowering the temperature. It is because of the high sealing temperature and also because the tube material is not compatible with the machine. Sometimes, leftover product on the sealing jaws also causes the material to stick.

Solution

Lower the sealing temperature, as mentioned in the plastic tube sealing machine manual. This problem could be resolved using non-stick sealing jaws and using materials that are compatible with machine components. Also, cleaning the sealing jaws leads to less material adherence.

Uneven Tube Seals

Uneven Tube Seals

Sometimes, there is variation in seal consistency from plastic tube to tube. There are differences in the shapes and patterns of seals. This problem is due to old and defective sealing jaws. Improper levelling of sealing jaws with plastic tubes can also cause uneven seals. Poor sealing pressure and distorted sealing plates can also produce variations in seals.

Solution

Replace old and damaged sealing jaws. Properly align sealing jaws and ensure uniform pressure distribution. Check for distortion in the sealing plates and replace them if necessary to prevent the problem of uneven sealing.

Scorching of Plastic Tubes

Scorching of Plastic Tubes

The materials of plastic tubes get burned due to high sealing temperatures and increased sealing time. If the sealing jaws are dirty and uncleaned, they are also the cause of the scorching of plastic tubes.

Solution

This problem is resolved by decreasing the sealing temperature and also reducing the dwell time. Properly cleaning the sealing jaws solves the problem of plastic tube burning.

Conclusion

Now it's time to wrap up the blog about the plastic tube sealing machine. Hopefully, you have found this piece of writing informative and engaging. A plastic tube sealing machine is a one-time solution to all your problems in filling and sealing. It is a sophisticated piece of equipment, carefully sealing the tubes to prevent product leakage. Planning this machine for your production? We Allpack are here to provide you with the best deals. Message us for machine purchase quote and other questions.

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Tablet Machine Press: The Complete Buying Guide In 2024

Tablet Press Machine

Tablet Machine Press: The Complete Buying Guide In 2024

Is your business related to tablet manufacturing? Does your process involve usage of a tablet machine press for making different types of tablets? Are you looking for a high quality and efficient tablet machine press? Does your system require a tablet machine press to enhance productivity and meet customer expectations?

If you want to know more related to a tablet machine press; then you are on the right platform. You will get all related information that will help you in selecting the right type of tablet machine press. Go through the complete guide and get solutions to your queries.

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1.What Is A Tablet Machine Press?

Automatic Rotary Tablet Press Machine

A tablet press machine is highly efficient and precise equipment used to produce uniform sized tablets of different shapes and formulations.

Pharmaceutical, food, cosmetics and chemical industries widely apply these machines in their tablet forming processes to get desired outputs with high productivity rate. These machine presses are mostly used in large scale industries where bulk tablets are produced with accuracy and same dosage formulation.

2.What Are The Industrial Applications Of A Tablet Machine Press?

Due to its ability to produce large numbers of tablets in a short period of time, a tablet machine press has variety of applications in daily life. Most of the industries that prefer these machines for their operations are:

Pharmaceutical Industry

Pharma Applications Of Tablet Machine Press - Picture Courtesy: Adinath International

Pharmaceutical industry widely uses tablet machine press for producing mass number of tablets with different tablet formulations. Each of the tablets has its own chemical composition and used to diagnose its relative disease. These machines are used due to their ability to form accurate drug content tablets keeping the dosage unique throughout the process. Also, tablets are of effective designs with brand name punched on it during production

Food & Nutraceutical Industry

Whole Food Multi-Vitamin - Picture Courtesy: Wholesome

Other than pharmaceutical industry, food and nutraceutical industries also have several applications of a tablet machine press. It is used produced different types of vitamins and minerals supplements that are consumed to improve physical health conditions. Some flavored candies and mints that in the shape of tablets are also produced using these machines.

Chemical Industry

Agricultural Tablets For Farm Growth

Chemically processed tablets that are employed in chemical, agricultural and refinery industries are manufactured using a tablet machine press. These tablets are used to enhance industrial process, fertilize agricultural lands and increase reaction rates respectively.

Cosmetics Industry

Hand wash Refill Tablets- Picture Courtesy: Jason

In terms of cosmetics, tablets that are used to promote human health both internally and externally are ideally produced using a tablet machine press. Unique types of tablets used for body wash purpose like fizzy coloring tablets and skin care tablets are also produced in an efficient way.

3.What Are The Advantages Of A Tablet Machine Press?

Some of the advantages of a tablet machine press are:

Efficient Production

Multi-Vitamin Tablets- Picture Courtesy: Efficient Group

The most important benefit of a tablet machine press is that it gives high rate of production in just a short interval of time with pure efficiency and precision. From loading of material to ejection of tablets, the complete process is performed in an efficient way without any chances of risk or improper formulation.

Uniformity

Uniform Tablet Punching - Picture Courtesy: Pharmaceutical Online

Each of the tablets produced in a tablet machine press is of same shape, size and dosage formation. This benefit makes the machine to ensure proper uniformity and consistency throughout the process that as it remain crucial of human health.

Dosage Control

Control Dosage Formation - Picture Courtesy: NB

A tablet machine press is capable of controlling dosage of different types of medicines in a precise manner that no over or under filing of material can be found.

Versatility

Pharmaceutical Dosage Form - Picture Courtesy: Walrus Health

A tablet machine press is versatile in a way that numbers of tablets can be produced in a single machine and there is no need to buy different machine for different shapes and sizes. Variety of formulations can easily be handled in it by just changing the turret size or dies according to the required shape.

4.What Are The Different Types Of Tablets Are Processed In A Tablet Machine Press?

Variety of tablets can be processed in a tablet machine press irrespective of their chemical composition and texture. These tablets highly obey regulatory compliances and international standards during their formation. Few of them are:

Chewable Tablets

IROWHIZ Plus Chewable Tablets - Picture Courtesy: Whiz Laboratories

Tablet machine press is also designed in a way that chewable tablets consumed by children can be produced in it easily. Supplements made of vitamins and antacids are included in the category of chewable tablets.

Effervescent Tablet

Benefits Of Effervescent Tablets - Picture Courtesy: Wellbeing Nutrition

Effervescent tablets are the tablets that contain sodium bicarbonate or citric acid in them that play their role as an effervescent agent. These tablets can easily be produced using effervescent type rotary tablet machine press that allows the impact remain for a longer period.

Laundry Tablet

Laundry Washing Machine Tablets - Picture Courtesy: Wash Wink

Laundry or solid tablets that are used for washing or detergent purpose are also manufactured using a tablet machine press. It completely dissolves in water and releases its active ingredient that supports in clean and authentic neatness of cloths and cottons.

Medicine Tablet

Antibiotics Tablets - Picture Courtesy: Anhui Medipharm Co. Ltd.

Simple pharmaceuticals tablets that contain an active ingredient and can easily be swallowed are termed as medicine tablets. These are punch in different shapes and size depending upon their stability and used for specific medical treatments.

Single Layer Tablets

Single Layered Tablet - Picture Courtesy: Medelpharm

Tablets that have a single layer of powder and compressed with force to form a tablet are single layer tablets. These are coating further to improve their stability and to make their taste remain for longer durations.

Multi-layer Tablets

Formulating Bi-Layer Tablets

Tablets with more than one layer of different formulations are called bi or multi layered tablets. These are consumed for treatment of controlled diseases with having more than one drug in its layer. Antidiabetic and antihypertensive drugs tablets are the example of multi-layered tablets.

5.How Is A Tablet Formed In A Tablet Machine Press?

Application Of Rotary Tablet Machine Press - Picture Courtesy: SED Pharma

A tablet machine press has following operational steps in formulation of a tablet:

STEP 1: Material Feeding

In the initial stage the formulated material in the form of powder or granule is filled into the hopper present at the top of a tablet machine press. From here the material in a homogeneous manner passes the feeding system and is entered into the die cavity.

STEP 2: Compression

In the second step once the material settles down properly in the die cavity, both the upper and lower punches are forced to compress the material to form the desired dimension and shape of tablet. Certain pressure is exerted so that the formation may be carried out in a controlled atmosphere and no material spillage may occur.

STEP 3: Ejection

The last step of a tablet machine press is ejection of tablets. Once the tablets are properly pressed according to the desired shape and size, the ejection system gets activated that removes the tablet from the die cavity. A conveying mechanism is incorporated here for travelling and collection of these tablets.

6.What Are The Types Of Tablet Machine Press Available Globally?

Tablet machine presses are classified on the basis of their working, production capacity and product type. Some of the common types of a tablet machine press are

Based On Working

Single Punch Tablet Machine Press

Single Punch Tablet Machine Press - Picture Courtesy: SED Pharma

Single punch tablet machine press is mostly used in small scale industries where the productivity remains low. This type of machine presses only a single tablet in the die cavity in a single punch and allows the second once it gets completely ejected from the system. The punching capability of this type of machine ranges 55 to 90 tablets per minute.

Flower Basket Tablet Machine Press

High Pressure Flower Basket Tablet Machine Press - Picture Courtesy: Changzhou Machinery

A flower basket tablet machine press is also used in small scale industries where smaller batches or tablets are produced. These machines are highly versatile that it can be used for electronics components, coffee pill formation and other tablets formation regardless of their nature.

A flower basket tablet machine has both force feed and compression principle that supports in efficient manufacturing of tablets. The working wheel of machine looks like a flower and this is why it is named according to it.

Rotary Tablet Machine Press

Rotary Tablet Machine Press

This type of tablet machine press is the most featured and arranged equipment that can accumulate large number of tablets in shorted periods. The turret of a rotary tablet machine press continuously moves and allows the feeding material to the die cavities. With series of punch sets, variety of shapes and sizes are punched in a single round. These machines are mostly used in large scale industries where the productivity remains high.

Based On Capacity

Depending upon the production requirement, tablet machine press is divided into two types

Small Capacity Tablet Machine

Low Capacity Tablet Machine Press - Picture Courtesy: Aipak

As the name indicates, this type of tablet machine press is designed for low-capacity manufacturing facilities that produce tablets for either testing or research purposes. Different types of granular or powdered material can easily be punched to produce many kinds of tablets.

Large Capacity/High-Speed Tablet Machine Press

High-Speed High Capacity Series Rotary Tablet Machine Press - Picture Courtesy: Aipak

A high-speed tablet machine press allows more than one tablet formation in a single round. It is most suitable for mass production setups where a greater number of tablets are produced in a shorter period. It is applicable to both medium and large-scale industries that produced irregular tablets, round shaped tablets and double sided engraved tablets.

Based On Products

Some of the tablet machine press are also classified depending upon the product they produce. Example of such type are:

Compressed Rotary Block Tablet Machine Press

Rotary Block Press (Compressed Biscuit Making Machine) - Picture Courtesy: Aipak

This type of tablet machine press is used in food industry due to compressed biscuits manufacturing. The biscuit powder undergo high pressure compression applied by both upper and lower punches and as a results gives tablet like compressed biscuits. These biscuits are used for a longer period as it remains fresh and preserved.

Effervescent Rotary Tablet Machine Press

Effervescent Rotary Tablet Machine Press - Picture Courtesy: Aipak

Some of the tablet machine presses also produce effervescent and aromatic tablets. These tablets are produced in a way that their aroma remains preserved for longer periods. It is a highly advanced machine that is developed with latest rotary mechanism in it.

Multi-Color Tablet Machine Press

Multi-Color Tablet Machine Press - Picture Courtesy: Aipak

Multi-color tablet machine press is used to produced large number of tablets with more than two colors in its formation. These machines have double press rollers in their structure that supports compression of multi colored layers with precision and accuracy.

7.What Are The Main Components Of A Tablet Machine Press?

Components Of A Tablet Machine Press – Picture Courtesy: Aipak Pharma

Some of the components of a tablet machine press are

Hopper

It is the main part of the feeding mechanism in a tablet machine press that holds the powdered or granule material used for tablet formation. The hopper is mostly made-up of stainless steel so that contamination can be avoided and it can be used for a longer period.

Organic Glass

The outer most transparent glass surface is made up of organic glass in a tablet machine press. This organic glass contains acrylic material composition that helps in safe guarding the inner part of the machine from external microbes or environmental factors.

Rotary Table

In a rotary tablet machine press, a rotary table is the place that contains the die cavities, upper and lower punches and cam turrets that are responsible for making of tablets. The upper punch moves up and down continuously for tablet formation whereas the movement of turret allows new material to enter and formed tablets to exit the system.

Adjusting Handle

The adjusting handle is used to adjust the speed of the rotary table and prevents material spillage.

Cam Truck

Tablet Press Cam Truck

Cam trucks are the one that supports and guide the movement of punches. Both of the upper and lower punch movement is first guided so that the material can be filled accurately first and then compressed to produce tablets.

Die Cavity

Die Cavities Of Tablet Machine Press - Picture Courtesy: Aipak

It is a hollow surface that is responsible to store the powdered or granular material in it that is to undergo tablet manufacturing. A die cavity is designed according to the shape of tablet and can easily be replaced for variety of batches.

Punches

Punches

Right Type Of Punch And Dies - Picture Courtesy: LFA Tablet Presses

Punches are mostly made up of stainless steel and in pair of upper and lower punch. Once the material is filled in the die cavity, both the punches compress the material with a certain force to form tablet.

Tablet Adjuster

Tablet Adjusting Mechanism - Picture Courtesy: LFA Machines

To avoid over and under filling of material, tablet adjuster is there to maintain the level of material and regulates the excess amount of tablet to maintain the composition and formulation.

Compressing Unit

Tablet Compression - Picture Courtesy: Pharma Education

A compressing unit a tablet machine press helps in providing the compression force in an automatic manner. The pre-compressor force exits air content from the die cavity and the main compressor force helps in forming tablets.

Operational Panel

An operational contains all the machine controls that are involved in the manufacturing of tablets. The speed of turret, upper and low punch, material feeding speed, temperature and other controls are present here that are directly in contact with the operator so adjustment can be done when required.

Discharge Port

This is the place from where the completely punched and produced tablets are taken out of the system. The discharge port acts as an ejection system in a tablet machine press.

Danger Button

A danger button is used in case of any emergency or machine failure. It directly stops the whole process and avoids any unwanted incident.

Electric Box

The relays and other electrical connection of a tablet machine press are present in the electrical appliance box that support machines working.

The electrical power whether its 110V, 220V or 440V is supplied to the machine through this power plug. It is used to power up the machine to perform its operation in a smooth manner.

8.What Is Tablet Tooling Of Tablet Machine Press?

Tablets tooling has the most fundamental role in tablet formation as it specifies which type, size and shape of tablet will be formed. The tablet tooling of a tablet machine press contains the die cavities and both upper and lower punches that are the essential blocks of any tablet formation. These can easily be changed according to the requirement.

Die Cavity

Die Table Of Tablet Machine

The die cavity holds both the upper and lower punches that are fixed with a turret. It is mostly made up of metal and has a defined shape and size according to that of a tablet. These are arranged properly to perform the compression process in an efficient manner.

Punches

Tablet Compression Tooling - Picture Courtesy: VORTEX

With the spinning of this turret, the upper punch moves downward to perform compression. The lower punch on the other hand holds the material that is to be compressed. The tablet tooling performs a synchronous operation for every punch so that each of the tablets remains identical and uniform.

9.What Are Different Diameter Of Tablet Dia Used In Tablet Machine Press?

Tablet Die And Punches Of Different Dia- Picture Courtesy: Shree Bhagwati

Different diameters of tablets dia are used in a tablet machine press according to the size and shape of tablet. These are mainly classified into B, D, BB and DB with standard barrel and outer diameters for lower and upper punches. The standard sizes of these tooling types are

S.NO	Tooling Type	Tablet Punch Barrel Diameter	Tablet Outer Diameter Of Die
1	D	25.40 mm	38.10 mm
2	B	19.00 mm	30.16 mm
3	DB	19.00 mm	24.00 mm
4	BB	25.40 mm	30.16 mm

These standards diameters of tablet tooling are used depending upon the size and shape of any manufacturing batch.

10.How Can Different Sizes Of Turrets Used In A Single Tablet Machine Press?

Tablet Press Turret - Picture Courtesy: Elizabeth Companies

Yes, Turret is a highly versatile equipment that it can easily be changed with respect to the tablet tooling set. They are interchangeable by easily swapping the base and allow the operator to adjust them according to the requirement. In this way a single machine can accommodate variety of turrets with flexibility.

In the operation of a tablet machine press, turret plays an important role as it is responsible to hold both the punch set and die cavity. Different types of machine use different number of turrets depending upon their productivity and structural support. A turret can support die sets ranging from 15 to 75 depending upon the size of machine.

11.What Are The Major Differences Between A Handheld Tablet Press And A Tablet Machine Press?

Difference Between Handheld And Tablet Machine Press

Some of the differences between a handheld tablet press and tablet machine press are:

S.NO	Parameter	Handheld Tablet Press	Tablet Machine Press
1	Structure	A handheld tablet press is smaller in size and can easily be moved from one place to another. It is lighter in weight and mostly made up of stainless steel to prevent corrosion.	The structure of a tablet machine press is quite complex as it has various components involved in tablet press process. These machines are designed in a way that continuous production can be support without any involvement of operator.
2	Productivity	Handheld tablet presses are operated by the operator and this is why its productivity is very low. The speed of the operator is directly related to the outcome of press.	Highly automated machines are now available that ease the manual operation and run the process in a smooth manner. Thousands of tablets can be produced in just a small fraction of time.
3	Precision	Due to the involvement of operator, the precision and accuracy of tablet formation remain limited as compare to the tablet machine press. Inconsistency can also be observed if the operator does not monitor the process continuously.	The productivity remains highly precise and accurate with consistent material composition in each of the tablet. Uniform tablets are produced using a tablet machine press.
4	Application	Handheld tablet presses are applied in industries that have small scale production volume or for research and development purpose.	Both medium and large-scale industries are the users of tablet machine press where tablets are produced in bulk quantity.

12.How Can The Efficiency Of Tablet Formation Remain Same Using A Tablet Machine Press?

It is always a crucial thing to maintain the efficiency of a tablet machine press same throughout the process so that tablets of identical shape and accurate composition can be formed. Some of the important factors to consider are:

Compression Force

Healthcare Medication- Picture Courtesy: Freepik

It is always important to check the applied compression force of upper and lower punch after a certain production batch. It is done to ensure that no over or under force is applied in tablet formation and the efficiency of system remains same.

Uniform Depth Filling

Uniformity In Tablets - Picture Courtesy: Natural Products Insider

Each of the tooling die cavity must be filled to its depth so that the desired tablets can be formed in an efficient manner. If the depth is not filled properly it will give uneven and improperly formed tablets.

Right Type Of Tooling Set

Tablet Tooling Sets - Picture Courtesy: Elizabeth Companies

Before performing tablet formation, it is always important to ensure that the right type of tablet tooling sets is fit into the turret. If this is not observed keenly than it can result a bulk amount of material loss.

13.How To Maintain A Tablet Machine Press For Its Smooth Operation?

Operation And Maintenance

A tablet machine press can be maintained by following ways:

Preventive Maintenance

Preventive Maintenance- Picture Courtesy: Korsch

It is always important to maintain a preventive maintenance chart and decide its frequency. Each of the part of a tablet machine press should be monitored according to its turn and replace if required to maintain the efficiency of the system.

Lubrication

Lubrication of Movable parts

As a tablet machine press has few moveable parts, it is important to keep them lubricated so that any type of wear and tear can be avoided. It can help in long usage of these parts in an efficient and precise way.

Controlling Excessive Wear

Controlling Excessive Wear- Picture Courtesy: Korsch

One of the important factors that can support in maintaining a tablet machine press is control of excessive wear. If the alignment of punches or die cavity is disturbed, it will automatically result in inconsistent movement and the compression process cannot be carried out in a smooth manner. It is always important to control this wear so that the operation can be performed efficiently.

Conclusion

A tablet machine press has variety of applications due to its high reliability and tablet formation features. It produces highly precise and uniform tablets of various sizes and shapes. But when it comes to buying a tablet machine press it is always important to understand its applications, types available and all related information. For this, Allpack is always here to provide you assistance and guidance related to a tablet machine press. If you still have any query feel free to contact our customer representatives that are available 24/7 for your guidance.

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Tablet Machine Press: The Complete Buying Guide In 2024 Read More »

Rotary Tablet Machine: The Complete Buying Guide In 2024

Tablet Press Machine

Rotary Tablet Machine: The Complete Buying Guide In 2024

With unprecedential advancements in technology, manufacturers are now looking forward for sophisticated equipment to boost their production instead of just switching the mode from manual to automatic. In such a scenario, when focus is more on efficiency, precision, and performance a rotary tablet machine is always the best choice for making tablets.

Rotary Tablet Machine is a complex machine designed with innovative features to tackle tablets manufacturing targets. It can raise your current output rate to the best possible one. But, how it can be possible with a single machine? What is the exact working mechanism of a rotary tablet machine? Are there further models of a rotary tablet machine? Just take a pause, as we are about to answer all of these queries. So, let's get started!

Add a header to begin generating the table of contents

1.What Is A Rotary Tablet Machine?

Allpack Rotary Tablet Press Machine ZP-5B

Rotary tablet machine, also known as multi-station tablet press, is an electric machine created to compress powders and granules into tablets. The machine uses automatic technology to carry out this task in a way where the dry mixture is precisely poured into relevant die cavities, compressed hardly, and the formed tablets are ejected out of machine.

This machine is highly efficient in its production while taking care of dosage. It is made up of GMP's regulated stainless steel body and a protected window. Moreover, it is highly versatile in terms of manufacturing different types of tablets. That's why its significance is realized in almost every sector.

2.Why Rotary Tablet Machine Is Important In Pharmacy?

Doctor picking drug pack- Picture Courtesy: wolterskluwer.com

The presence of a rotary tablet machine is inevitable in pharmaceutical industry due to the nature of manufacturing in this field. This machine has gained a position of importance in pharmacy due to multiple reasons among with the prominent one is efficiency.

Rotary tablet machine produces thousands of tablets in an hour which make it possible to deliver required drugs to patients all around the globe. Another reason is the protection of medication mixture which is highly considered in pharmacy because minor mistake can ruin the effect of drugs. But here the machine is proficient in forming precise tablets.

3.Write Down The Benefits Of A Rotary Tablet Machine?

Rotary tablet machine can be advantageous for you in multiple ways. Below highlighted benefits are some of the prominent ones:

Efficiency

Bilayer tablets discharging from machine- Picture Courtesy: ibermaticoss.com

Rotary tablet machine is known for its consistent working process which ultimately leads to the production of myriad of tablets in a single run. Hence, its efficiency can enhance your manufacturing output.

Safety

Safety

Drug safety presentation idea- Picture Courtesy: iStock

By using a rotary tablet machine, you will not be bothered to take the risk like manually intervening into the operation if spontaneous error occurs, rather pressing emergency button will stop the machine. Similarly, the protected body of machine is highly antibacterial that it safely processes the mixture without modifying its characteristics.

Convenience

Rotary tablet machine promotes user convenience due to its easy-to-use operation panel through which operator can communicate with the machine. Moreover, the machine does not require number of labours, but single user is enough to run the machine.

Resilience

Bilayer tablets- Picture Courtesy: europeanpharmaceuticalreview.com

Rotary tablet machine is highly resilient due to its capability to press eclectic sizes and shapes of tablets. Moreover, there is wide collection of rotary tablet machine models which enable you to form bilayer, multilayer, and effervescent tablets.

Reliability

Manufacturers look for cost-effective machines to cut the production costs of tablets. In this way, a rotary tablet machine is extremely reliable which requires low maintenance, single operator, and ultimately reducing the additional expenses.

4.What Type Of Tablets Can Be Made By A Rotary Tablet Machine?

All kinds of small to large with different sizes and shapes tablets can be made by a rotary tablet machine. Below is the glimpse of these all:

Single Layer Tablets

Patient holding single layer tablet in hand- Picture Courtesy: usana.com

Single layer tablet is a standard type of tablet where single Active Pharmaceutical Ingredient is delivered to patients. Such tablets are always perfectly formed by a rotary tablet machine.

Bilayer Tablets

Bilayer tablets- Picture Courtesy: Fette Compacting

As the name indicates, bilayer tablets are tablets containing two separate powered mixture compacted together. Their process of formation occurs in a way where first powder mixture is compressed and then second powder mixture is introduced over the formed tablets and compressed together. Such bilayer tablets can be easily made by a rotary tablet machine.

Multilayer Tablets

multilayer tablets- Picture Courtesy: bharatagritech.com

Multilayer tablets refer to the tablets having three distinct dosages compacted together. The purpose of making multilayer tablets is to provide three different Active Pharmaceutical Ingredients in a single tablet paving the way for effective drug delivery. Therefore, a rotary tablet machine is capable to form multilayer tablets.

Effervescent Tablets

Effervescent tablets- Picture Courtesy: solife.blog

Effervescent tablets are also called carbon tablets which are extra large in size than standard tablets. They are designed to quickly dissolve in liquid, therefore, most of the effervescent tablets contain calcium dosage and energy dosage. Here, it is pertinent to mention that a rotary tablet machine can be used to form effervescent tablets.

5.How Does A Rotary Tablet Machine Function?

The working process of a rotary tablet machine is based on certain steps where a turret moves in rotary direction and lead the powder to turn into tablets. This process can be better understood in by reading the underlying explanation:

Filling

Filling

Powder Filling- Picture Courtesy: LFA Machines

The first step is filling where bulk powder or granules mixture is filled into the hopper of machine. From hopper, the powder flows to feeding unit known as feed frame. This feed-frame then evenly distribute the powders into each passing die cavity.

Metering

Powder Metering- Picture Courtesy: LFA Machines

The second step is metering which is also known as dosage or weighing. In this step, the precise amount of powder is weighed after which the lower punches move upward to remove excess powder from die bore.

Compression

Tablets compression- Picture Courtesy: LFA Machines

In third step, the upper and lower punches are brought together with force to form the tablets. The compression stage can be further divided into pre-compression and main compression.

In pre-compression, the upper punch descends to press powder with little force for creating a slug to remove air pockets. After this, in main compression, both the upper and lower punches are brought together with much force which result in the formation of uniform tablets.

Ejection

Tablets ejection- Picture Courtesy: LFA Machines

In last step, the upper punches move upward followed by the rise of lower punches in ejection can. Similarly, the tablets are ejected out of the die bore towards scrapper. The scraper then moves down the formed tablets down the ejection track into the container.

6.Describe The Various Components Of A Rotary Tablet Machine?

Rotary tablet machine consists of several components which together help the machine to form tablets making function. These parts are explained below in detail along with the main task each perform. So, consider the following description:

Components of Allpack ZP25 effervescent rotary tablet press machine

Hopper

Hopper is sometimes called the feeder system of a rotary tablet machine. You will always find the location of a hopper on the top side of machine. The number of hoppers depends upon the type of machine; however, the common hopper is one or two in number. It provides the machine with dry powdered or granulated mixture.

Stainless Steel Body

The body of the machine is compact and robust that greatly contributes to supporting a stable operation. It is made up of GMP's regulation stainless steel material, which is fully protected against bacteria and corrosion, therefore, material is processed inside it.

Rotary Table

Rotary table is the core component of a rotary tablet machine which distinguishes it from other types of machines. The table itself is made up of further parts including:

Turret:It is the vital part of a rotary tablet machine with round structure having multiple holes where dies and punches are adjusted. During tablets compression, this turret rotates and lead dies and punches to compress powder.

Punches:Rotary tablet machine has two punches; upper punch and lower punch. These are durable stainless steel rod type tools having on their tips or heads the specific shape. Punches are vital in compressing powders into tablets through exertion of force.

Dies:Dies are among crucial components of a rotary tablet machine. They are small round tools with a single or multiple grooves where the lower and upper punch meet in order to compress the powder into tablets.

Compression Rolls:Compression rollers are cylindrical rollers who perform the function of pressing powder. They are two in number including pre-compression rolls and main compression rolls. The former compress powder to remove air, while as, the latter exert excessive pressure to form tablets.

Cam Tracks:As the name indicates, cam tracks are tools which provide track for the synchronized movement of punches.

Organic Glass

Rotary tablet machine has a transparent protected window that enable the user to monitor tablets making process without touching it.

Operation Panel

Operation panel is a board containing touch screen display and certain knobs through which the user set commands in machine such as the quantity of powder for each tablet, the thickness of tablets, and compression force etc.

Emergency Stop

Emergency stop is a red colored large size button located on the front of a rotary tablet machine. It is a safety switch used to shut down the machine in an emergency.

Electric Appliance Box

It is consistent the most vital component of a rotary tablet machine where all the electrical components are collectively placed for supporting smooth functioning.

Adjusting Handle

Adjusting handle is used to modify the force of compression roller.

Discharge Chute

This part of machine is responsible to exit the formed tablets from machine into a collection container.

7.Are There Any Types Of A Rotary Tablet Machine?

There are multiple types of rotary tablet machine available in market today. This wide classification has been introduced to meet the growing demands on part of manufacturers. So, let's explore these types in detail!

According to Automation

Automatic Rotary Tablet Press Machine

Automatic Rotary Tablet Press Machine

Automatic rotary tablet press machine is the most advanced form of rotary tablet machine. It is fully automatic in technology with production output reaching the figure of 17000 tablets per hour. This machine can be integrated with other machines to further enhance the efficiency.

Structure

The structure of machine is robust and complex which is an assembly of several small to large components. These include a stainless-steel body, transparent window, control system, electric enclosure, turret, hopper, punches, dies, compression rollers, and a touch screen penal.

Working Process

It is fully automatic, therefore, automatically dispense the powder from hopper onto feed frame and die cavities simultaneously. Afterwards, the pre-compression and main compression take places. At last, the formed tablets are removed out from die bores through ejection.

Semi-Automatic Rotary Tablet Press Machine

Semi-Automatic Rotary Tablet Press Machine

Semi-Automatic rotary tablet press machine is small design machine with good production capacity of producing 1000 tablets per hour. The machine is easy-to-use and cost-effective in price. Different small to medium size industries can take advantage of this machine.

Structure

The structure of machine is small made up of several components including a metallic base, stainless steel hopper, turret, control board, compression rollers, and a motor etc.

Working Process

The machine is manually loaded with powder formula and powered on. It then automatically fills the die cavities, compresses the powder and eject formed tablets from die bore and discharge into the laying container.

According to Sides

Single Sided Rotary Tablet Press

Single Sided Square GMP Mini Tablet Press- Picture Courtesy: deepujpharmamachinery.com

Single sided rotary tablet machine is a common type of machine with single hopper and single rotary table. However, despite being a single sided equipment this machine can give you excellent production rate of compressing 4800 to 18000 per hour.

Structure

The structure of machine is medium size compared to double sided rotary tablet machine. It mainly consists of a single hopper, one turret, operation panel along with certain knobs, and an electric appliance box.

Working Process

It follows the conventional working procedure by filling the dies with powder. Afterwards, precise amount of powder is kept inside the dies and rest is removed. The filled powder is then compressed to form tablets. When the punches reach to ejection cam track, the formed tablets are ejected from the machine.

Double Sided High Speed Rotary Tablet Press

Double Sided High Speed Rotary Tablet Press- Picture Courtesy: deepujpharmamachinery.com

This is another type of a rotary tablet machine which is tailored with excellent tools and double rotary punches to achieve utmost productivity. In this machine, the powder is fed into two turrets from double sides. Therefore, its production efficiency is double than a single rotary tablet machine with compressing 2,66,400 tablets in an hour.

Structure

The structure of machine is a composite whole of double turrets, two hoppers, four adjusting handle, enclosed body, control system, and electromechanical tools etc.

Working Process

It simply works in a way where one hopper is responsible to provide powder to the die cavities located in upper turret, while as, another hopper feed the die cavities of the lower turret. Similarly, both these turrets undergo compression stage and ultimately, discharge the compressed tablets through single discharge chute.

According to Layers

Bilayer Tablet Compression Machine

Bilayer Tablet Compression Machine- Picture Courtesy: deepujpharmamachinery.com

Bilayer rotary tablet machine is featured with innovative technology to form bilayer tablets by compressing two formulations into single tablet. It has high efficiency level and can be used in nutraceucal, pharmaceutical, and food industries.

Structure

This machine has relatively a precise body with several parts accounting for its construction including two funnels, single turret, pre-compression and main compression rollers, multiple adjusting handles, and electric enclosure etc.

Working Process

It works by infusing the first formulation into die cavities and compress them. The turret them move and leading these die cavities to be filled with second formulation. After this, the main compression exert force on punches leading the creation of uniform bilayer tablets. Finally, tablets are ejected from the dies.

Multilayer Tablet Press Machine

Multi Layer Tablet Press Machine- Picture Courtesy: deepujpharmamachinery.com

Multilayer tablet press machine is the most updated model of a rotary tablet machine with the ability to form three-layer tablets. It greatly ensures the precision of each dosage layer with the help of integrated sampling facility for weighing and checking. Moreover, it can be employed in food, medical, and chemical industries.

Structure

It consists of three hoppers, heavy-duty machinery, feeder system, compression rollers, emergency stop, turret, control panel, and discharge chute etc.

Working Process

The working process of a multi layer tablet machine is a bit unconventional with intermittent filling of powders into dies and their subsequent compression. Firstly, individual powder mixtures are poured in separate feeding hoppers. Secondly, when the turret start moving, one powder mixture is filled in die cavity and get compressed.

This die cavity is then filled with another powder mixture and compressed where two layers get formed. Thirdly, the same die cavity is then filled with distinct powder mixture and a final compression take place. Finally, the formed tablets are ejected and discharged.

8.Differentiate Between Rotary Tablet Machine And Single Punch Tablet Machine?

Rotary tablet machine and single punch tablet machine are used for making tablets but their structure, working process, and many other aspects are different from each other. Therefore, we have explained these differences in the table below for your clear understanding:

No	Factors	Rotary Tablet Machine	Single Punch Tablet Machine
1	Definition	Rotary tablet machine is a multi station rotary press machine that compress powder with upper and lower punch.	Single punch tablet machine is the earliest form of a tablet press machine with single punch.
2	Structure	Its structure is complex and containing different components.	While as single punch tablet machine is small in size and consists of fewer parts.
3	Number of punches	It has set of upper and lower punch.	On the other hand, this type of machine has only a single upper punch.
4	Process	Its process is convenient due to automation but has several stages.	In contrast, the working process of a single punch tablet machine is straight forward.
5	Speed	It is highly efficient with capacity of producing 800 tablets in a minute.	In contrary, this machine can compress 80 tablets per minute.
6	Cost	It is expensive than a single punch tablet machine.	While as, this machine is cost-effective.
7	Picture	Allpack Rotary tablet press machine ZP-7B	Allpack TDP series Single punch tablet press

9.What Are The Uses Of A Rotary Tablet Machine?

A rotary tablet machine has extensive applications which can be better understand by looking into the below highlighted sectors:

Pharmaceutical Industry

Coated oblong tablets- Picture Courtesy: tabletscapsules.com

Rotary tablet machine is widely used in pharmaceutical industry to meet the excessive need for producing different kinds of tablets and pills with varying shapes and sizes.

Nutraceucal Industry

Nutraceucal drugs display- Picture Courtesy: depositphotos.com

As the growth rate of nutraceucal industry is surpassing other sectors, it can be said that demand for formation of large number of tablets is also growing. Hence, a rotary tablet machine is inevitable to fulfill this production target.

Veterinary Industry

Doctor treating a dog- Picture Courtesy: stock.adobe.com

Tablet is considered the most convenient and desirable form of dosage which can be easily swallowed by pets and animals as well. Therefore, veterinary industry uses a rotary tablet machine to make abundant tablets.

Food Industry

Malt tablets packaging- Picture Courtesy: roscela.com

Among other areas food sector is the notable one. Here, you will find number of confectioneries in form of bilayer and multilayer tablets like milk tablets, chocolate tablets, and other tablets made from compacting salt and dyes. So, a rotary tablet machine can be used in various food industries.

Chemical Industry

Chlorine tablets in hand- Picture Courtesy: tennisamatoriale.it

The application of a rotary tablet machine can also be found in chemical industry where chemical powders are compressed to form tablets and then used for different purposes. In this way, chlorine tablets are the common example.

Pesticide Industry

Tree & shrub tablets- Picture Courtesy: marriedtoplants.com

We are familiar with the fact that the health of plants is always in danger due to harmful pests and insects. That's why different techniques have been employed to tackle this issue by restricting the access of these organisms to plants. Similarly, pesticides have been enclosed in tablets for which a rotary tablet machine is used.

10.How To Examine The Quality Of A Rotary Tablet Machine?

In order to examine the quality of a rotary tablet machine, you can simply check the certifications of the company. In this way, below highlighted quality standards are internationally recognized ones whose compliance will indicate that the machine is made up of quality material:

ISO

International Organization for Standardization is an international organization established to ensure the credibility and safety of goods and products. Therefore, if a rotary tablet machine is ISO certified, it is made up of quality material.

GMP

Good Manufacturing Practices is yet another platform created to guarantee the hygiene and purity of a rotary tablet machine. So, a machine complying with GMP regulations will be of high-quality standard.

FDA

Food and Drugs Administration is USA based agency with primary goal to provide safe and healthy drugs and associated equipment. Therefore, a rotary tablet machine which is used for making drugs must meet with the FDA's rules.

CE is the collective marking of European Union made to allow the mobilization of only those products which are conforming the Union's health, safety, and environmental protection standards. Hence, presence of this mark on a rotary tablet machine will strengthen its quality.

11.What Machines Can Be Integrated With A Rotary Tablet Machine?

Rotary tablet machine can be integrated with other machines to facilitate larger production output. The list of these machines has been provided below:

Tablet Deduster Machine

Allpack Top rotation type tablet deduster machine SZS230

Tablet deduster machine is one of the essential equipment that can be attached to a rotary tablet machine. It is used to remove out the dust and residues from tablets after their pressing. It consists of a main frame, chassis, vacuum device, dust collection plate, infeed, and outlet etc. It works by following the principle of vibration.

The mechanical force generate vibration which results in tablets scattering and moving over perforated plate. At this point, the dust is collected through vacuum device and tablets are free from dust.

Tablet Coating Machine

Allpack tablet coating machine BYA-600

Tablet coating machine is another equipment that can be integrated with rotary tablet machine. It is employed for coating the tablets with thin coating film. Several components constitute its body including a coating pot, heating device, control panel, and machine base etc. It coats the tablets by continuously rotating them in a coating chamber where fluidized coating formula is sprayed over the tablets resulting in even coating.

Tablet Counting Machine

Allpack APC-8 Automatic Tablet Counting Machine

Tablet counting machine is the most important machine which go side by side with rotary tablet machine. It has been designed with automatic technology to count the tablets through sensors and vibratory trays and then fill these counted tablets into various bottles and containers. It is made up of several parts comprising a hopper, vibratory channel, counting compartment, filling head, and automatic detection system.

Blister Packaging Machine

Allpack DPP-180H High Speed Tablet/Pill/Capsule Alu Alu Blister Packaging Machine

It is a primary packaging machine mostly used for tablets packaging. This blister packaging machine is used to create blister packs in round or oblong shape to hold tablets and pills. The machine uses, film roll, thin aluminum foil, heating system, and detection system to precisely form the blister packs, accurately place the tablets in blister packs, and seal them through aluminum foil.

12.How To Maintain A Rotary Tablet Machine For Smooth Functioning?

Regularly maintaining your rotary tablet machine can enhance the working life of the machine and also keep its pace at good condition. In this way, below discussed are some of the notable tips whose following will help you achieve the maintenance of a rotary tablet machine:

Lubricating mechanical parts of machine- Picture Courtesy: geartechnology.com

Dusting & Cleaning:No doubt, cleaning is the obligatory part of maintaining a rotary tablet machine. So, you need to dedust the parts of machine after the machine complete one round and wash these parts when daily task gets done. These parts include the hopper, fill parts, compression rollers, dies and punches. Parts like control panel, handle, and control board can be wiped out with cloth.

Lubrication:Lubrication is another important step in maintenance of a rotary tablet machine. Here, you need to lubricate the transmission parts of machine-like rollers to improve their motion fluency.

Parts Changeover:After cleaning and lubrication, it is significant to have a look towards the damaged parts of machine. If you find components in unsuitable condition, then make sure to timely change them with new spare parts.

13.Troubleshoot The Common Pitfalls Of A Rotary Tablet Machine?

When operating a rotary tablet machine, it might show malfunctions that can lead to bigger challenges like tablets breaking and capping etc. These pitfalls are caused due to technical issues that occur inside the machine. To troubleshoot these errors timely you need to have relevant knowledge about it which is given in the table below:

No	Pitfalls	Causes	Solutions	Pictures
1	Tablets capping happening after compression	The reasons are trapped air inside die cavity and the excessive dry nature of powder.	It can be tackled by increasing the dwell time of pre-compression stage, so, the air will get more time to come out. Also, make sure the powder has enough lubrication to make it compact.	Capping of tablets- Picture Courtesy: romaco.com
2	Lamination of tablets	Over compression is the core reason for lamination of tablets where they get cracked. Another reason can be the use of inappropriate dies.	So, you need to enhance the pre-pre-compression time to lead powders stick together and use tapered dies which are best for avoiding tablets lamination.	Laminated tablets- Picture Courtesy: sciencedirect.com
3	Tablets particles stick to the punch tips or heads	It is one of the serious issues that occurs as a result of particles being wet from inside leading them to stick to punch head. In some cases, the punching tools are also responsible for particles picking.	The solution lies in properly drying the powder mixture after its wet granulation tool place. Moreover, increasing the dwell time of pre-compression roller will give time to powders for drying. Along with that, daily polishing of punching tools will highly reduce the chances of tablets sticking to their heads.	Tablets sticking to punches heads- Picture Courtesy: researchgate.net
4	Tablets binding happen inside the die restricting way for tablets ejection	Too much binding agent causes tablets' sides to take hold in die cavity which can make them crumble when ejected.	Reduce the lubrication or binding agent in tablets and make sure the mixture is well dried.	Tablets with rough sides- Picture Courtesy: asme.org
5	Tablets friability	Tablets’ friability leads to challenges in their coating, packaging and delivery. It has various reasons encompassing the low number of binders, excessive compression speed, and large granules with no fine powder.	Solution is simple, you need to add sufficient binders into mixture, reduce the compression force of machine to suitable level, and reduce the size of granules.	Broken tablet- Picture Courtesy: eastmedpharmacy.co.nz

14.What Are The Instrumental Considerations For Purchasing A Rotary Tablet Machine?

Purchasing a rotary tablet machine means including in your production line a determiner who will determine critical things about your business such as the manufacturing output, size and shapes of tablets, and cost of production. So, make sure you are choosing this machine attentively!

Production Capacity

Capacity puzzle- Picture Courtesy: adults.ccinform.co.uk

The first and most critical factor to look for is the production capacity which you are planning to have. Since, there rotary tablet machine is available both in automatic, semi-automatic, single sided and double sided form, you can opt according to your needs.

Shape & Size of Tablets

Different sizes & shapes of tablets- Picture Courtesy: shutterstock.com

Another crucial consideration comes on part of the tablets' shape and size. Here, you have to pick for right assembly of punches and dies whose specifications are compatible to your desired ones.

Type of Feeding System

Rotary tablet machines come with two types of feeding system: open feeder and closed feeder. Open feeder has poor flow ratio, which is good for granulated mixture compression, while as, closed feeder has fluent feeding frequency and is suitable for powders. So, make sure you opt for the rotary tablet machine with an intended feeding system.

15.What Is Allpack Line Of Rotary Tablet Machines?

Allpack is providing a suitable collection of rotary tablet machines. Have a look towards it!

No	Machine	Production Capacity Per Minute	Number of Dies
1	Allpack rotary tablet press machine ZP-5B	9000 tablets	5
2	Allpack Rotary tablet press machine ZP-7B	12600 tablets	7
3	Allpack Rotary tablet press machine ZP-9B	16200 tablets	9
	Allpack Rotary tablet press machine ZP-7B	17000 tablets	11

Conclusion

We are wrapping up this buying guide about a Rotary Tablet Machine with great enthusiasm and a hope that you have found this piece of writing a helpful one. Rotary tablet machine is the answer to all problems that are being faced by today's manufacturers in medical field, food sector, and pesticide industry. It is the most updated version of tableting machinery as proved by the above discussed vast classification of a rotary tablet machine. So, now it's your turn to revolutionize your tablet making business. If you are eager to learn more, stay in contact with us!

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Powder Packaging Equipment: A Complete Buying Guide in 2024

Powder Packaging Machine

Powder Packaging Equipment: A Complete Buying Guide in 2024

How to pack powders? A top piece of equipment called powder packaging equipment has prime importance in every industry because almost every industrial sector of the world processes and packages powder one way or another.

Integration of the powder packaging equipment slowly but steadily has been on the rise. The need for automated technology to promote productivity has fueled the growth of powder packaging equipment. Also, increased demand for on-the-go packaging styles has led to increased adoption of powder packaging equipment in the industrial sector.

If are you looking for a solution that safely and hygienically packs your powder products then we recommend installing powder packaging equipment in your production. But before that, first, carefully read this guide to discover more about this useful machine.

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1.What is a Powder Packaging Equipment?

Powder Packaging Equipment

Powder packaging equipment is a versatile and handy manufacturing and filling unit that efficiently packages different types of powders in a wide range of packaging containers. It loads and contains powders in sturdy and airtight packaging containers for mess-free and leakage-proof shipment, retailing, handling, and delivery.

This machine typically forms, fills, and seals different types of packaging containers like pouches, sachets, stick packs, bottles, jars, vials, etc. Due to its diverse benefits, it is used in a broad range of industries like food, pharmaceutical, beverage, cosmetics, and many more.

2.Why Use a Powder Packaging Equipment?

Powder packaging equipment is an automated unit, flexible and robust capable of handling different packaging containers. Adopting this manufacturing unit is beneficial for industries. We are discussing some important benefits of this machine for your ease.

Improve Accuracy and Lower Wastage

Improves Accuracy by Powder Packaging Equipment- Picture Courtesy: All-Fill

Humans are more prone to mistakes which leads to lower accuracy. This in turn causes increased profit loss by overfilling or product rejection by underfilling. But by adding powder packaging equipment in the production, you are assured of accuracy. This machine has sensitive measuring devices that increase accuracy and reduce product wastage.

Better Product Quality

Better Product Quality by Powder Packaging Equipment- Picture Courtesy: Packaging of the World

By performing repetitive tasks, humans get tired, consequently making more packaging errors like wrongly packaging products, overfilling, or underfilling. With automated powder packaging equipment, product quality is ensured. It safely and consistently packs products with no chance of error.

Lower Labour Costs

Lower Labour Cost by Powder Packaging Equipment- Picture Courtesy: All-Fill

Labor comes with high costs, especially when you calculate different types of pay and training expenses. Although, the powder packaging equipment is a hefty investment in the longer run it earns more than its initial investment by requiring less labour force. This translates to lower labour costs and high benefits.

Versatility

Versatility by Powder Packaging Equipment

The powder packaging equipment is a handy and flexible investment, capable of processing a broad range of powders. It is useful for industries that pack multiple products every shift. Moreover, it can handle varying ranges of pouches, jars, sachets, and many more differing in their designs and sizes.

Fulfills Packaging Demands Easily

Fulfills Demands by Powder Packaging Equipment- Picture Courtesy: CVC Technologies

More orders mean more profit. But with handfilling, it is difficult to meet such rising requirements. However, with powder packaging equipment, you can easily fulfil high demands and satisfy more customers. This machine quickly packages more products and produces more orders in a short time.

3.What is the Design of a Powder Packaging Equipment?

The design construction of the powder packaging equipment is detailed below for your understanding.

Both Pictures Represent Parts of the Powder Packaging Equipment

Motor	It is an electric component that offers powering energy to different machine components for continuous machine operation. It converts electric energy into mechanical energy and moves filling devices, conveyors, sealing systems, etc.
Hopper	It is the hollow square or cylindrical chamber of powder packaging equipment that houses bulk quantities of powders.
Measuring Cup	The function of the measuring cup is to measure and dispense the correct quantity of powders inside the packaging container.
Alarm System	It is a safety feature that notifies operators of faults in the machine by lighting up and sounding an alarm.
Touch Screen HMI	The programming of the machine operation is done by touch screen. It is the interactive feature present in modern powder packaging equipment that assists in monitoring its performance.
CNC Process Bag Forming Part	It is a technologically advanced part that accurately and precisely forms the packaging bags using packaging film. It ensures that the formed bags are of the right dimensions and perfect quality.
Sealing System	It consists of horizontal and vertical sealing jaws and it fuses different edges of packaging film to create airtight seals that result in leak-proof bags.
Cutting Device	It consists of sharp cutting knives that cut the edges of the two bags for their exact separation.
Auger Filler	The function of this component is to dispense an accurate quantity of powders in the packaging container. It is a closed device ideal for the contamination-free filling of powders.
Conveyor	This part consists of drive belts and chains and is featured in a powder packaging equipment for the transportation of containers between different packaging stations.
Caster Wheel	The caster wheel provides mobility to the machine. They rotate to move the powder packaging equipment from one place to another.
Height Adjustment Screw	This part is a screw-like device with which conveyors are moved up and down to accommodate different-sized containers.

4.What is the Useful Application of Powder Packaging Equipment?

Numerous products come in powdered form, so powder packaging equipment is needed by several important industries. Some of the useful industrial applications of the powder packaging equipment are:

Pharmaceutical Industry

Use of Powder Packaging Equipment in Pharmaceutical Industry- Picture Courtesy: Dieline

The powder packaging equipment is employed in the pharmaceutical industry for the packaging of different kinds of antiemetic powders, antiseptic powders, pain relieving powders, etc. It also packs different cannabis powders in both flexible and rigid packaging containers. It hygienically packs aseptic pharmaceutical powders in vials and bottles.

Nutraceutical Industry

Use of Powder Packaging Equipment in Nutraceutical Industry- Picture Courtesy: Packaging of the World

This machine is high in demand in the nutraceutical industry to uphold production efficiency. It fills accurate dosages of nutraceutical powders like supplement powder, protein powders, minerals, probiotics, prebiotics, dietary fibre powders, etc in strong packaging safely and precisely.

Food Industry

Use of Powder Packaging Equipment in Food Industry- Picture Courtesy: Dieline

It is the most demanding industry, where the powder packaging industry is utilized because different kinds of food products are available in powdered form. It loads food powders like flour, spices, coffee, sugar, salt, baking soda, baby formula, herbs, seasoning, curry powders, milk powders, etc.

Beverage Industry

Use of Powder Packaging Equipment in Beverage Industry- Picture Courtesy: Dieline

Yes, powder packaging equipment is utilized in the beverage industry for packaging different kinds of beverage powders like instant juices, coffee, iced tea, powdered juices, and other kinds of beverage powders. Single-pack sachets are an important factor that improves the utilization of this machine in the beverage industry.

Chemical Industry

Use of Powder Packaging Equipment in Chemical Industry- Picture Courtesy: Dieline

The powder packaging equipment is used in the household chemical industry for safely and securely packaging different types of sensitive chemical powders like laundry powders, bleaches, paint pigments, washing soda, alkali salts, detergent, dishwashing powders, and cleaning powders. It also fills agrochemical powders like fertilizers, pesticides, and herbicides, etc.

Cosmetic Industry

Use of Powder Packaging Equipment in Cosmetic Industry- Picture Courtesy: Dieline

This machine holds the promise of accurately and elegantly packaging cosmetic powders like face powders, dyes, dusting powders, eye shadows, and blushes, to name a few. It gently loads specialized cosmetic products in classy pouches and premium jars for captivating high-end customers.

Coating Industry

Use of Powder Packaging Equipment in Coating Industry

This industry deals with the creation of paints, resins, polishes, varnishes, furniture polishes, whitewash, finishes, and primers. The powder packaging equipment is used in this industry to airtightly package these coating powders to prevent their deterioration by environmental elements.

Construction Industry

Use of Powder Packaging Equipment in Construction Industry- Picture Courtesy: Packaging Connections

In the construction industry, different kinds of construction powders are processed and packaged by the powder packaging equipment. It loads sealant, additives, cement, silica, grouts, etc. in bulk quantity pouches. A seamless packaging with a speedy workflow is carried out by the powder packaging equipment in the construction industry.

5.Explain the Working Steps of the Powder Packaging Equipment.

Product Loading

First, the infeed tanks are employed for storing the powders inside rectangular or conical hoppers, typically present on the top. The powders from the hopper flow into measuring cups. The latter are equipped with weighing devices that dispense exact quantities to the filling nozzles.

Filling

Filling

A powder filling machine is featured with a rotating auger which is helpful in flowing powder without interruption as it pushes powder forward toward filling nozzle.

Upon presence of filling containers or any packaging type, machine senses it and allows an optimized concentration of powder to fill inside.

Discharging

In the next step, the final discharging of filled container takes place toward the next integrated unit.

6.What are the Types of the Powder Packaging Equipment?

Different types of powder packaging equipment are seen in the industries, each customized for specific packaging operations. These types vary in their filling devices, automation, number of channels, design configuration, and structural construction. Below is the detail of the classification of the powder packaging equipment:

According to Filling Types

Auger Powder Packaging Equipment

Auger Powder Packaging Equipment

It is routinely used in the powder-filling industries because of its simple and quick filling of powders. It is a closed structure that hygienically fills the powder with no chance of contamination. Auger screw assists in the fluidity of powders by rotation. Powder passes auger devices smoothly and precisely.

Volumetric Cup Powder Packaging Equipment

Volumetric Cup Powder Packaging Equipment

This machine consists of several cups in the tray. A precalculated amount of powders is loaded inside the cup by the hopper and then these cups dispense a precise amount of powders in the container. This machine is well-suited for consistent particle size and free-flowing powders.

Positive Displacement Powder Packaging Equipment

Positive Displacement Powder Packaging Equipment

It uses pistons and pumps for the loading of powders inside the container. Rotation of pumps and to and fro motion of the piston displace powders from the hopper and dispense them in containers. This machine processes a wide range of products such as free-flowing powders.

Weigh-based Powder Packaging Equipment

Weigh-based Powder Packaging Equipment

This machine is popular in mass-scale productions because it can easily process large batches of powders. Unlike other powder packaging equipment, this machine dispenses quantities of powders by measuring their weight. A weigh-based powder packaging equipment uses load cells or other balancing parts to calculate the weight of the products.

Gravity Powder Packaging Equipment

Gravity Powder Packaging Equipment

This machine has simple design construction with straightforward working. Using gravitational force, the powders trickle down into the container. It is a valve for controlling the filling rate. It is best for free-flowing powders.

According to Automation

Manual Powder Packaging Equipment

Manual Powder Packaging Equipment

It is a simple and convenient machine, affordable for small industries, research centres, and pharmacies. It has a smaller footprint and is often placed on the desktops. It has rotating levers and handles for filling. It is labour-intensive because operators have to perform loading and unloading by hand.

Semi-automatic Powder Packaging Equipment

Semi-automatic Powder Packaging Equipment

It is a compact-sized machine that is best for medium-sized industries. It occupies a smaller space in the production. Loading and unloading of containers is manual in this machine while filling is automatically performed under the control of the machine’s PLC unit. It is recommended to use this machine if you do not require a higher processing speed.

Automatic Powder Packaging Equipment

Automatic Powder Packaging Equipment

It is an outclass machine with its up-to-date controls and modern gadgets. It is needed when higher volume production is required because of its exceedingly higher output. This machine requires a minimal number of operators for programming the HMI of the machine. Other functions like forming containers, filling powders, and unloading containers are executed independently.

According to Number of Channels

Single-Head Powder Packaging Equipment

Single-Head Powder Packaging Equipment

This machine as the name suggests, has only one filling head or nozzle. The powders flow into this nozzle so it packs one container in one cycle. This means it has a lower production capacity, so it is usually found in smaller productions. However, it has a simple design configuration, so it is quite budget-friendly.

Multi-Head Powder Packaging Equipment

Multi-Head Powder Packaging Equipment

It is a complicated design machine with many filling heads, thus it can pack multiple containers in one go. Large industries with heavier processing install this kind of powder packaging equipment because of its higher output rate. It comes with a higher price tag and needs more room for its installation.

According to the Design Configuration

Linear Powder Packaging Equipment

Linear Powder Packaging Equipment- Picture Courtesy: WeighPack

It is constructed in a straight line and has a U, Z, or L-shaped configuration. Filling heads are arranged one after another for filling multiple containers. The containers travel using a conveyor. However, it operates at slower speeds as the movement of the conveyor pauses for filling. But it has the benefit of compact construction and simple maintenance.

Rotary Powder Packaging Equipment

Rotary Powder Packaging Equipment- Picture Courtesy: CVC Technologies

It is constructed with a rotary carousel with multiple stations arranged around its circumference. It is fast because it does not stop during the filling steps. It has higher productivity but it is difficult to clean and maintain this machine because of its complicated design.

According to Packaging Types

Pouch Powder Packaging Equipment

Pouch Powder Packaging Equipment

It is a popular machine because pouches processed by this machine are favourite among buyers and sellers. This machine fabricates pouches on its own; hence, it is customized to produce different styles of pouches. It is fast, versatile, and is dominating the packaging world.

Sachet Powder Packaging Equipment

Sachet Powder Packaging Equipment

This kind of powder packaging equipment is adopted in the industries because it forms small single-serve sachets that are popular among on-the-go customers. It has a compact and simple design usually containing one lane; therefore, it has limited processivity.

Premade Pouch Powder Packaging Equipment

Premade Pouch Powder Packaging Equipment

This machine is perfect in such a way that it processes already-made pouches that can be customized according to brand image. This machine has a rotary turntable with different processing stations, consequently, it carries out pouch filling and sealing at much higher rates. Due to the rotary turntable, it has a complicated design construction and a much higher purchase price.

Stick Pack Powder Packaging Equipment

Stick Pack Powder Packaging Equipment

This machine forms, fills, and seals small single-serve stick packs. It features four, eight, twelve, sixteen, or twenty lanes which is why it can perfectly and swiftly pack large stick packs during one cycle. It has a larger footprint than a sachet powder packaging equipment.

Bottle/Jar/Vial Powder Packaging Equipment

Bottle/Jar/Vial Powder Packaging Equipment

It has a different design construction, unlike above mentioned machines because it consists of single long conveyors and an arrangement of multiple filling heads. The containers for filling are loaded on the conveyor.

According to Structural Construction

Opened Powder Packaging Equipment

Opened Powder Packaging Equipment

This machine is an open system, where filling heads freely pack powders without using any specialized device. This machine is commonly seen in industries and is used for packing different kinds of powders that do not require any special loading conditions.

Closed Powder Packaging Equipment

Closed Powder Packaging Equipment- Picture Courtesy: HUDIA Packing Machine

For loading sensitive and hygroscopic ingredient powders, closed powder packaging equipment is employed in the industries. This machine has an enclosed chamber in which vacuum systems are used for drawing and fluidity of powders. Unlike other powder packaging equipment, that agitate powders, this equipment gently processes powders.

7.Does the Powder Packaging Equipment Include Anti-Dust Emission Devices?

Yes, the powder packaging equipment includes anti-dust emission devices to stop the production of dust. These are the safety features because if they are not present with the powder packaging equipment, the dust emitted may spark, causing severe accidents in the workplace. These devices include:

Dust Collection Hoods

It is an anti-dust emission device that is equipped with closed hoods. These hoods catch the powder dust at the filling stations.

De-aerators

De-aerator- Picture Courtesy: DirectIndustry

These are the devices that draw the air from the powders to prevent dust generation. The air pockets are eliminated by using de-aerators which play a significant role in dust production.

Vacuum Suction System

Vacuum Suction System- Picture Courtesy: FRITZ EMDE

By using vacuum systems, the powder packaging equipment draws the dust from the filling points. In addition to dust suction, it increases the cleanliness of the powder packaging equipment and prevents powder contamination.

Air Filtration Systems

Air Filtration System- Picture Courtesy: Matcon

These instruments can be installed in the powder packaging equipment that filters the dust from the air and recirculate filtered air. This improves the ventilation of the production floor.

Anti-Static Devices

Anti-Static Devices

These devices produce an electric field around the filling systems and transform static charges that may cause sparks by charging the powder dust.

8.Does the Powder Packaging Equipment Process Granules?

Powder Packaging Equipment

Yes, powder packaging equipment can be configured to handle granules. Some types of powder packaging equipment have dedicated systems that are only used for powders. However, these types of machines are customized to process granules by changing filling devices and program settings.

Nevertheless, numerous types of powder packaging equipment can process both powders and granules. These instruments have interchangeable parts that assist this equipment in transiting between both types of products.

9.What is the Difference between a Powder Packaging Equipment and a Liquid Packaging Machine?

Liquid Packaging Machine

Both of these machines have a similar objective- packaging products- however, both these machines have varying designs, packaging operations, and industrial applications. The powder packaging equipment and liquid packaging machine differ in the physical nature of the product. Some key differences in these machines are:

Features	Powder Packaging Equipment	Liquid Packaging Machine
Nature of Product	This machine, as the name suggests packs solid particles- powders.	This machine processes liquid products. It processes both free-flowing and viscous products.
Filling Devices	The powder packaging equipment employs an auger, volumetric cups, and also a weigh filler to correctly load the powders.	It typically uses a pump, piston, overflow, and gravity fillers.
Packaging Container	It typically stores products in pouches, bags, stick packs or sachets.	It fills products in jars, bottles, and pouches.
Design	It has a complicated design due to the presence of anti-dust devices, vibrators, deaerators, and agitators.	It has a simpler design construction.
Applications	It loads spices, herbs, curry powders, tea, pigments, dyes, etc.	It packs water, juice, honey, condiments, pastes, sauces, fuel oils, and many more.

10.What are the Frequent Issues and Their Troubleshooting in the Powder Packaging Equipment?

Sometimes, unanticipated issues occur in the powder packaging equipment, leading to troublesome production delays. If these issues are not handled correctly then expensive repairs bring about serious monetary issues. However, we are detailing some tips and tricks to resolve such frequent problems in the powder packaging equipment.

Inconsistent Packaging Weight

Inconsistent Packaging Weight

Cause

Remedy

Poor powder flowability.

Out-of-order weighing scale.

Powders are of varying sizes.

Increase the product flow by using different kinds of agitators.

Fix and recalibrate the weighing scale.

To decrease variations in powder particle sizes, first premix different powders.

Clogged Filling Nozzles

Product Buildup and Clogged Filling Nozzles

Cause

Remedy

There is a build-up of sticky powders inside the nozzles.

Powders are tightly packed inside hoppers or other filling devices.

Presence of foreign products in the powders.

Adhere to a proper cleaning schedule and thoroughly clean parts that come in regular contact with powders.

Inspect the moisture ratio in the powders and store the powders under low humidity settings.

First, filter the powders before loading them in the hopper.

Bursting of Powder Pouches

Bursting of Powder Pouches

Cause

Remedy

Inconsistent pouch seals.

The packaging materials are of substandard quality.

Overloading of powders inside the pouch.

Alter the sealing parameters and ensure sealing jaws are working correctly.

Re-purchase high-quality packaging materials that fulfil packaging specifications.

Adjust the filling parameters on the touch screen and ensure fill accuracy.

Powder Spillage and Dust Generation

Powder Spillage and Dust Generation- Picture Courtesy: JBT Corporation

Cause

Remedy

High filling speed.

Incorrect alignment of filling nozzles with packaging containers.

Poor dust control approaches.

Reduce the fill speed.

Ensure that packaging containers are correctly placed under the filling nozzles.

Install dust control devices.

Incomplete or Poor Sealing

Cause

Remedy

Inadequate temperature and pressure while sealing.

Contaminated surface of sealing jaws.

Defective sealing jaws.

Wrinkled packaging film.

Insufficient sealing time.

Ensure accurate temperature and pressure while sealing.

Clean the exterior of the sealing jaws.

Replace damaged sealing jaws.

Use packaging film of high quality.

Provide adequate time for sealing.

Conclusion

Powder packaging equipment has prominence in different industries because it processes a broad range of powders swiftly and accurately. This machine is adaptable, cost-effective and all-rounder in its performance. The powder packaging equipment is the most desired globally because of its efficient and timely powder packaging. To answer your queries regarding the powder packaging equipment, we at Allpack are always available. For further assistance and selection guidance, please contact our ever-ready customer care.

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Liquid Packaging Essentials: 3 Important Details You Must Know

Liquid Filling Machine

Liquid Packaging Essentials: 3 Important Details You Must Know

Dealing with packaging of liquid formulation is always tricky and requires a lot of expertise. Do you know why? Because there are more chances of spillage, equating temperatures, dealing with viscosities, and much more. Therefore, having proper knowledge about liquid packaging equipment, the type of packaging required, capacity, and application is paramount.

Stepping into liquid packaging production?

Try making this plan as stress-free as possible. Today, liquid packaging has gained a lot of attention and high market demand due to frequent usage in pharma, food, beverage, and many other industries.

Be awesome and make the liquid packaging process simplify. Here we have elaborated Liquid Packaging Essentials: 3 Important Details You Must Know; the purpose of designing the article to deal with your inner stress and making the project easy for you. So read and try implementing the points.

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1.Never Ignore Temperature Regulation

Several Liquid Packaging Are Temperature Sensitive- Picture Courtesy: meghmani dye

For any liquid packaging, considering the right temperature associated with a respective product is really important to maintain the quality and potency of the ingredients.

This is the foremost factor that every liquid packaging has to pass through transportation, shipping, and other delivery methods.

Therefore, the packaging material must be of a kind that can preserve the internal environment as favorable as required.

	Medicine	Food	Nutraceuticals	Cosmetics
Ambient Temperature	15°C - 25°C	15°C - 25°C	15°C - 25°C	15°C - 25°C
Refrigerated Temperature	2°C - 8°C	2°C - 4°C	2°C - 8°C	2°C - 8°C
Freezing Temperature	Below 0°C (-15—40)	Below 0°C	Below 0°C	Below 0°C

A table demonstrates different temperature essential for liquid packaging- Source: Specialist Pharmacist Service

The change in temperature can mess up the quality of the inside product. For instance, there are various medicinal products that are sensitive to external environmental conditions. You need to keep its temperature maintained. The ambient temperature for medicinal products is preferred between 15ºC and 25ºC” or “below 30ºC” . Similarly, the refrigerated items must be between 2 and 8ºC. These medicines are commonly referred to as “cold chain” medicines or “fridge lines”. Those liquid products are prone to go bad early ultimately wasting a huge amount of money, and energy, and affecting the health system.

Therefore, for liquid packaging, you must consider the necessity of the temperature of the particular packaging item to control the environment and use the packaging material that is best fit for your formulation to deliver promising products.

Things To Do!

Temperature-controlled liquid packaging essentially protects the perishable liquid items from destabilization, change in potency, taste, and other relevant parameters. It is important to keep liquid packaging insulated against the mentioned factors.

Not only does it lose its valuable potency and efficacy but so called it puts your formulation in a danger zone to progress microbes inside and lead to food poisoning upon ingestion.

Therefore, for liquid packaging follow the points:

Insulated Liquid Packaging

PLA liquid Packaging

There are various insulated liquid packaging that can keep your business awesome as it will keep the temperature well controlled during transit. For example, using PLA or Polylactic acid packaging which has thermal insulating properties that can keep the temperature around 4ºC for up to 30 hours then can rise to 25 to 30ºC. This packaging is safe and does not contaminate or releasing unwanted fumes. That’s why it is popular in food, pharmaceutical, nutraceutical industries.

Use Temperature Indicator

Temperature Indicator Strip

Today, you can find high-technology color-changing temperature indicators used as liquid packaging essentials that are not only indicating but known as effective sensors by highlighting unacceptable temperature range exposure. This is beneficial as it helps in satisfactory deliveries, helps in storage under various climate conditions, and accurate demonstration of temperature even in below -18C, or temperatures between -3C and 10C.

Well-Controlled Liquid Packaging Machine

Allpack Liquid Packaging Machine

A good liquid packaging machine is also significant for liquid packaging which should specifically feature temperature controlling properties and be capable of dealing with various products packaging for sensitive pharmaceuticals, drinking, and other liquid packaging.

2.Knowing about Liquid Particle Size

In some liquid preparations, you will observe various particle sizes suspended in them. This is known as suspension.

On the other hand, formulations like condiments, salads, and similar products are also composed of suspended particulates. The filling of such items requires much concentration as they cause clogging of the filling passage inside the machine.

Therefore, you must assess the nature of particles and the type of working principle used by the machine. The commonly used particle sizes in liquids used in the chart below:

Type of Liquid	Particle Size
Suspension	Greater than 100nm
Solution	Less than 1 nm
Colloid	Less than 100 nm but greater than 1nm
Granules Aggregate	Greater than 1000 µm
Coarse Particle	Size varying from 100 µm to 1000 µm

Table is referred from Boomeria.org

Allpack semi-automatic piston filler is recommended for liquid with various suspended particulate.

For those particles that are composed of a large surface area, the liquid packaging can be done using a ‘piston filler’ which features a unique filling nozzle that helps in addressing the easy flowability of such items.

Moreover, this filler is appreciated for using products like salad, jams, and relevant foodstuffs as it ensures that molecules with larger surface area can be dealt with easily. This is because a piston can push and accelerated the process very well. The material stored in the hopper can be received and pushed using piston pressure.

Suspended Particles in the Mixture- Picture Courtesy: DayNatural

Some particles are suspended in the liquid due to the high thickness of liquids, for filling them you need to constantly stir the solution to keep liquid solution uniform and well-dispersed.

It is essential to ensure that a uniform and even number of particulates are filled and packed inside the filling material. This can be achieved by constant agitation and stirring processes to bring their products with tremendous output. Also, it minimizes the settling of particulates bottom of the hopper or tank.

Things to Do!

Nevertheless, dealing with liquids with various particles size is challenging but side by side there are various types of equipment came into emergent that can break large particles and make them up to your requirements and make the process easier.

Use Homogenizer or Mixers

Allpack Vacuum Emulsifying Mixer for Uniform dispersion of particles with high-speed shear

When making suspension in food and pharmaceuticals, manufacturers are frequently demanding machines like cone mills, rotor stators, emulsifying mixer homogenizers, and ultra-sonic homogenizers.

The homogenizers work by using shear forces, impaction or cavitation (reducing particle sizes). Each of these machines gives you promising output with a high guarantee that the liquid solution is packed with uniform and equal distribution of particle sizes.

3.Viscosity of Liquid Solution & Packaging

Viscous Liquid Products

If liquid resists flow and shows thickness, it is known as viscosity. This means, it is internal friction develops inside the molecules of fluids so you can feel thickness which is termed as a viscous liquid.

Well, what viscosity has to do with packaging?

This is very important known as products with high viscosity resist motion and exert more internal pressure than normal liquids. It does not flow and pack more easily as you expect. Similarly, liquids with lower viscosity molecules tend to flow more easily and form less friction when packaging them.

Therefore, every manufacturer must know the viscosity of the liquids they pack. For that we are giving a mathematical formula, which is helpful in measuring the viscosity of the products. Such as:

Viscosity = Shear Stress / Shear Rate

μ = τ / γ

The unit of viscosity is expressed in ‘centipoise or cps.

There are standard viscosity of water which is ‘1cps’. Similarly, the viscosity of the honey shows a viscosity approximately 10,000 cps, while mustards or ketchup demonstrates a viscosity ranges between 50,000 - 70,000 cps.

The viscosity ranges must be known to you as during packaging more viscous liquid consumes greater time inside the machine’s circulatory units to reach final dispensing into the packaging material. Therefore, you should be able to select the machine that must be capable to run, and inducing the pressure to flow liquids smoothly till packaging without over or under-flowing liquids.

Things to Do!

You Should Know Viscosity Measurement

The rheology is very important- picture Courtesy: College of London

It is measured by a specialized device known as ‘viscometer and rheometer.

A viscometer is used to measure Newtonian liquids in which viscosity is not dependent on shear forces such as water, urine, etc., whereas a rheometer is used to measure non-Newtonian fluid, where liquids change their viscosity depending upon pressure or stress applied. For example, kinds of ketchup, sauces, etc.

That’s why it is recommended to shake the bottle of ketchup or viscous solutions as its viscosity becomes decreases upon good shaking. The liquid packaging viscosity is affected by heat, that’s why it is recommended to warm syrups with high thickness to make less viscous during packaging in industrial packaging.

Using A Good Mixing Equipment

Mixing Liquid- Picture Courtesy: Elephango

As mentioned above, mixing can lower the thickness or viscosity of the liquids, therefore, blending time, agitator rate, and selection of impellers are very important which alter the characteristics of solutions.

A blending time and speed of agitation is significant that’s why choosing the right design and selection is paramount to achieve an efficient mixing speed.

High Shear Mixer Liquids- Picture Courtesy: Syntegon

For high-viscosity blending, use a low-shear impeller, it will maintain uniformity in the liquid tank and make cleared liquid flow. Whereas a high viscosity impeller is recommended for high viscous solutions to keep them uniform in the blending tank.

Impeller used for low (Propeller) and High (Anchor) Viscous Liquid

Low Viscous Liquid

A propeller and turbine impeller are used for mixing low viscous liquids to keep uniform consistency inside the liquid molecules.

High Viscous Liquids

An anchor impeller and Gate impeller is needed for mixing highly viscous liquids as they promote an axial flow and suitable for thick slurries.

Conclusion

It's time to automate your filling task by knowing ‘Liquid Packaging Essentials 3 Important Details You Must Know’. Whether you’re filling sauces, thick slurries, syrups, or elixirs, the modern liquid packaging machine has turned this difficult job pretty quickly and easily. However, if you consider the right supplying company like Allpack, it would make your decision ‘super-tremendous’. This is because Allpack cares for its customers by offering expert guidance and an amazing liquid filling line in a cost-effective way. Want to Make a quick Purchase? Please contact our team now.

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Powder Filler: The Complete Buying Guide in 2024

Powder Packaging Machine

Powder Filler: The Complete Buying Guide in 2024

Are you looking for an efficient and cost-effective approach to fill your powder products? Then Powder Filler is the best option for you. This is the equipment which allows you to correctly fill the packet boxes with the constant amount of dry goods while also speeding the manufacturing process.

Powder Filler Machine- Picture Courtesy: Resalexportusa

We are going to discuss everything you want to know about Powder Filler. By the end of this article, you will be able to select your choice that can enhance your production capabilities. So, let’s get started.

Add a header to begin generating the table of contents

1.What is a Powder Filler?

Powders Filler

Powder filler is equipment that precisely fills dry, granules, and other powered materials into predefined packaging materials. The devices ensure the guarantee that goods are filled correctly according to the weight or volume of powder.

The powder filler can be utilize for filling a variety of items from food, spices to pharmaceuticals, cosmetics and industrial chemicals. These machines come in different sizes; from table ones to fully automatic filling lines.

2.What are the benefits of Powder Filler?

Benefits of Powder Filler- Picture Courtesy: Mediaamazon

Powder filler provides various advantages to the packaging businesses.

Accuracy

Accuracy

The powdered goods are filled accurately and efficiently which results in uniform dosing and reduced in product waste.

Multi-Functional

Multi-Functional

Powder fillers are multifunctional and work with wide ranges of powders, granules, and even materials with hazardous properties.

High-Speed

High Speed

The powder fillers may also be modified to fit in specific manufacturing needs, especially speed, container size and filling abilities. Moreover, powder fillers can boost the production by automating the filling process, saving manual human errors, and increasing output. Powder fillers enhance the packaging efficacy, productive quality, and cost effectiveness.

3.What are the Parts of Powder Filler?

Parts of Powder Filler

The powder filler have numerous parts based on the models and design of the machine. However, some common parts of Powder fillers are:

Servo Motor

The servo motor is a type of motor that precisely and accurately controls its position, speed, and torque through a closed-loop system. It helps in correctly filling containers with powdered substances. The servo motor allows for smooth and precise movements, which improves the overall performance of the powder filler.

Mix Motor

The mix motor in the powder filler is responsible for filling the powder. It assures that the powder is evenly distributed and mixed completely with no inconsistencies. It is typically made of motor-driven mixture that moves and rotates inside the hopper or mixing chamber.

Feeding Material

The feeding material in powder filler is used to fill materials into the containers. It can be any type of powder, including food ingredients, pharmaceuticals, and industrial powders. The powder filler is intended to handle and dispense the feeding material precisely and efficiently.

Level Sensor

The level Sensor in powder filler is a device that monitors and controls the amount of material fed into the machine. It ensures that the correct amount of powder is available for filling and prevents the containers from being over and under filled.

Touch Screen

The touch screen in powder filler is a user interface that allows operating and changing the settings of the machine by touching the screen. It makes it easier to control and analysis of the filling process.

Material Hopper

The material hopper in powder filler is a vessel that contains the powder material before it is dispensed in the packing. It ensures the powder flow and increase the filling process.

Power Switch

In powder filler, the power switch controls the machine’s power supply. It enables you to turn the machine on and off, supplying the electrical power required for the powder filler to operate. The power switch is a critical component for running the machine safely and efficiently.

Filling Nozzle

The nozzle part in the powder filler dispenses the powder in the package. It helps with the flow control and direction of the powder that result in precise filling.

Feedback Scale

The feedback scale in powder filler is a measurement scale that provides information about the weight and volume of powder being dispensed. It promotes accurate and consistent filling by monitoring and adjusting the amount of powder dispensed based on the desired weight or volume.

Leakage Material

The term leakage material includes excess powder or dust that has escaped from the machine due to poor sealing or handling. It is critical to ensure proper maintenance and sealing to avoid any potential leaks or spills while operating the powder filler.

4.Are there any Types of Powder Filler?

There are various different types of powder filler available in the market. Some includes:

Manual Powder Filler

Manual Powder Filler

Manual powder filler are usually manually operated and use measuring spoons to fill the packages with a precise amount of powder. It is best suited for small or medium production requirements and can be in small and large batches.

Semi-Automatic Powder Filler

Semi-automatic Powder Filler

Semi-automatic powder filling machine is ideally used for small businesses with limited budget and requirements. Semi-automatic powder filler helps to fill the container boxes with powdered materials. It needs some manual support from the operator during the filling process. It’s the great tool to improve efficiency in packaging.

Automatic Powder Filler

Automatic Powder Filler

Automatic powder filler machine is designed to automatically fill package containers with powdered substances. It automatically controls the mechanism to accurately measure and disseminate the powder into the packages, improving the efficiency and reducing human errors. Automatic powder fillers are commonly used in industries such as food, pharmaceuticals, and chemicals.

5.What is the Industrial Usage of Powder Filler?

Powder fillers have numerous uses in different industrial areas. Some major industries that require the powder filler equipment’s are:

Pharmaceutical Industry

Powder Filler in Pharmaceutical Industry

The powder filler correctly dispensed the medicine and drugs in various packages, either in glass bottles or sachets.

Food and Beverages Industry

Powder Filler in Food and Beverages Industry

Powder fillers have vital role in food and beverages, the industry often pack coffee powder, fine flour, milk powder, spice powder, and sugar powdered product by the fillers.

Chemical Industry

Powder in Chemical Industry

In chemical industry, powder filling machine is necessary for the filling of both mild and reactive chemical products like ammonium chloride, carbonate powder, copper sulfate crystal, malic acid powder and etc.

Cosmetic Industry

Powder Filler in Cosmetic Industry- Picture Courtesy: Midum

Powder filler can also be used in cosmetic industry as a few products like baby powder or other cosmetic items filled accurately by the machine.

Agriculture Industry

Powder Filler in Agriculture Industry

Powder filling machine is effective in packing of powdered organic and inorganic fertilizers in agriculture industry.

6.What Type of Packages can be Filled Using Powder Filler?

There are different packaging materials used in powder filler. Some of them include:

Bottles:

Bottles

Bottles

The powder filler frequently use bottles to fill powder products. These bottles usually come in different size and shapes. Bottles are often composed of glass, plastic, or metal.

Jars:

Jars

Jars are similar as bottles except it have wider opening. They are mostly utilizing for the goods like food items, and powder products. Jars comes in plastic and glass form.

Pouches:

Pouches

Pouches are flexible packaging material containers usually composed of aluminum foil or plastic.

7.What is the Working Mechanism of Powder Filler?

Powder Filler Machine

Powder filler typically consists of a hopper that stores the powder. The powder is then fed into a filling chamber using a feeding mechanism. Powder filler is used to measure and dispensed powder into containers such as bottles or bags.

The powder filler mechanism can be gravity-based, auger-based, or piston-based depending on the type of powder and level of accuracy required. Once the containers are full, they are sealed or closed with the appropriate sealing. Sensors and programmable logic controllers (PLCs) control the filling process on the powder filler, which operates automatically. This allows for precise and efficient filling of the powder into the containers.

8.What are Different Filling Types of Powder Filler?

Powder fillers are used in different industries to do powder packaging efficiently. Some types of powder fillings are as follows;

Gravity Based Fillers

Gravity Based Fillers

They are called gravity-based fillers because of the reason that they use gravity to fill in the container with the powdered product. They consist of a hopper through which the powder flows down which is driven by gravity. And hence they are the perfect choice for free-flowing but may be not very appropriate for other filling methods.

Volumetric Fillers

Volumetric Fillers

They are named volumetric because of the volume of the product to dispense a fixed amount to get filled in the container. They go perfectly for consistent density and particle size. Mostly use cylinders, cups and chambers to measure the volume of powder.

Augar Fillers

Augar Fillers

They have an auger (rotating auger) which helps to fill in the powder with precision. It rotates at a controlled speed to fill it at a consistent speed. The auger filler is suitable for free and non-free flowing powders as it shows speed and high accuracy.

Weight Based Filler

Weight Based Filler

These sorts of fillers work on by weighing the weight of the product and with the help of weight, they fill the powder in the container. The machine is useful to work with powder particles of different densities and states.

9.What Is the Production Line of Powder Filler?

It involves many key compounds to ensure efficient and accurate filling, capping, sealing and labeling. But always remember there is a typical production line for a powder filler.

Bottle/Container Unscrambler

Allpack Bottle Unscrambler

The unscrambler machine aids locating , orienting, and organizing the empty bottles/containers in their proper place to supports the filling process. It takes help of vibratory plate and rotation of the disc that allows positioning of containers.

Capping Machine

Allpack Capping Machine

Once filling is done, the containers are moved to the capping machine where caps and lids are applied to make the container secure and protected during transportation.

Induction Sealing Machine

Allpack Induction Sealing Machine

In the case of powder products, additional sealing is required to maintain freshness and prevent tampering, which is where the induction sealing machine comes in to create a hermetic seal between the container and lid.

Labeling

Allpack Labeling Machine

Finally, containers move to the labeling machine to apply labels containing product information, branding, and other relevant information that helps the product get marketed efficiently.

10.How to Maintain a Powder Filler?

Powder Filler- Picture Courtesy: Bellatrex

This is true that powder filler requires upkeep. Frequently maintenance extends the machine’s life span and helps to guarantee peak performance. Some typical maintenance factors are:

Cleaning: To get rid of buildup or residue, clean the powder filler on a regular basis. Use the recommended cleaning agents and adhere to the manufacturer’s instructions for correct cleaning techniques.

Lubrications:The manufacturer advises inspecting and lubricating the powder filler’s moving components. This guarantees smooth operation and helps lower friction.

Inspection:Check the machine frequently for indications of wear, damage, or loose parts. Deal with any problems as soon as possible to avoid more harm or interruptions appearing.

Calibration:To ensure precise dosing and filling, calibrate the powder filler on a regular basis.

Replacement of Wear Parts:As necessary, replace any worn out or damaged components, such as filter, belts, or seals. By doing this, possible problems are avoided, and the machine’s performance is maintained.

11.What are the Quality Compliances of Powder Filler?

Quality Compliance

In order to maintain the quality and efficacy of filled products, the powder filler must strictly uphold by multiple standards and regulations. The following are some vital elements of powder filling machine quality compliance:

Good Manufacturing Practices (GMP): The powder filler is designed, used, and maintained in accordance with GMP rules and regulation that guarantee products quality and avoid contamination.

International Organization for Standardization (ISO): The quality standards for the management system are created by ISO 9001, and medical devices are the subject of ISO 13485. These guidelines helps in assuring reliability in both quality and customer satisfaction.

Food and Drug Administration (FDA): The powder filler are used in pharmaceutical and food packaging industry have to uphold the FDA regulation in order to secure product safety, effectiveness, and proper labeling.

European Hygienic Engineering & Design Group (EHEDG): Powder fillers and other machines used in the food and beverage industry are covered by the hygienic design rules and regulations provided by EHEDG.

National Electrical Manufacturers Association (NEMA):NEMA provides the standards for electrical equipment that support environmental, performance and safety requirements.

12.What considerations are before Buying Powder Filler?

Several factors should be taken in consideration before purchasing powder filler. Some important things to think about are:

Production Capacity: This establishes the expected goals and confirms the powder filler can fulfill your production needs.

Powder Characteristics: Consider the particular characteristics of the powder, like its density, moisture content, and workability that you will be using to fill it. Make sure the powder filler is appropriate for using with the powder you have.

Accuracy and Precision: To preserve product quality and cut down on waste, look for powder filler that provides excellent dosing and filling accuracy and precision.

Flexibility: Determine whether the powder filler can accommodate your product range by handling a variety of container size, shapes, and packaging formats.

Ease of Use and Maintenance: Think about the machine’s ease of use, encompassing its setup, operation, and maintenance aspects. Seek for features that make cleaning simple, fast replacements and maintenance part easily assessable.

Safety Features: Verify that the powder filler has enough safety features, like protective guards, and emergency stop buttons, to guarantee operators safety.

Conclusion

Every producer’s dream is to own a productive and successful powder filler line. In order to assist you in selecting the type of machine, you should ensure the consistency of the product. The best automated gadgets might then be taken into the consideration if you want to gain accuracy and efficacy. The output and ability to adhere to manufacturing quality are the last things you must overlook. Feel free to contact Allpack team for more information and queries about powder filler.

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Handheld Tablet Press: The Complete Buying Guide In 2024

Tablet Press Machine

Handheld Tablet Press: The Complete Buying Guide In 2024

Are you a business owner that involves usage of a handheld tablet press? Are you interested in buying a high-quality handheld tablet press to improve your productivity? Are you interested in investing in a handheld tablet press? Does your industry involve tablet pressing process? Want to know more regarding a handheld tablet press? This is the forum where you can get all the related information that will support you in selecting the right type of handheld tablet press. Read the complete guide to resolve your queries.

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1.What Is A Handheld Tablet Press?

Handheld Tablet Press

A handheld tablet press is a portable equipment used in various industries to manually compress powdered or granular materials into tablets.

It has a press mechanism, die cavity, and a handle for manual operation, making it ideal for small-scale or laboratory applications. These presses provide a simple and cost-effective way to produce tablets with precise dimensions and consistent weight.

2.What Are The Applications Of A Handheld Tablet Press?

Allpack Handheld Tablet Press Applications

Handheld tablet press has numerous uses depending upon the size and shape of tablets. Some of the applications of a handheld tablet press are

Pharmaceutical Industry

Formulating Pharma Tablets - Picture Courtesy: PharmaTech

Pharmaceutical industry widely uses handheld tablet press for its clinical trials and initial testing purpose. Some of the small-scale pharmaceutical industry also applies handheld tablet press to produce efficient and unique type of tablets. Many clinical trials are also carried on using a handheld tablet press as it can be easily adjusted for different formulations and produce accurate samples.

Herbal Industry

Herbal Tablets - Picture Courtesy: Candy Room Sweets

Herbal industry also uses handheld tablet press to make precise and consistent dosage of medicines. This helps in preventing material loss and also standards the productivity with keeping the quality consistent in each tablet.

Nutraceutical Industry

Manufacturing Nutraceutical Tablets - Picture Courtesy: Nutraceutical Business

Formulation of supplements and vitamins produced in nutraceutical industries are mostly carried out using a handheld tablet press. These tablets are produced for testing and research purpose in small scale industries. Press is feasible to use and also efficient in producing nutraceutical tablets.

Cosmetics Industry

Glutathione Niacinamide Beauty Tablet - Picture Courtesy: APLB

Most of the skin and health care tablets produced in cosmetics industry are manufactured using a handheld tablet press. These tablets are easily produced by high quality pressing and material mixing capability of a handheld tablet press.

Fertilizer And Agricultural Industry

Tree Grow Fertilizer Tablets- Picture Courtesy: Northwoods Tree Farms

Fertilizers and pesticides that are important for the growth of plants to provide them a controlled growth and to keep insects away are also processed using a handheld tablet press. Agricultural sector uses these handheld tablet presses for formulation of unique types of tablets.

Research And Development Labs

Research & Development - Picture Courtesy: Bora Pharmaceuticals

Handheld tablet press is also used for on field research and development purposes. They are used in field applications or remote places where larger-scale tablet pressing equipment is unavailable or unfeasible.

3.What Benefits You Can From A Handheld Tablet Press?

There are several advantages of a handheld tablet press. Some of them are

Flexibility

Flexible Use Of Handheld Tablet Press

Handheld tablet press is highly efficient when it comes to their mobility and accommodation. These can easily be moved from one place to another and are flexible in handling. Handheld tablet press allows quick changes to formulas and forms. Tablets of any size and shape can easily be produced using a handheld tablet press.

Handling

Handheld Tablet Press - Picture Courtesy: Automatic Rotary Tablet

The press has simple operation that does not requires any expert training. The controls are provided and guided for exact tablet compression.

Customization

Design Tablet Tooling

Another benefit of a handheld tablet press is that it can be changed easily according to the required shape and size of tablet. The machine is easy to customize by just changing the die cavity of required tablets within a small fraction of time.

Waste Reduction

Several Efficient Medical Tablets Designs

Handheld tablet press ensures that no material of tablet is send on account of wastage and also reduced material spillage. It maintains the composition of tablets and saves a lot of resources.

4.What Types Of Tablets Are Processed In A Handheld Tablet Press?

Some of the types of tablets that are processed in a handheld tablet press are

Immediate And Extended Release Tablets

Immediate Release Tablet - Picture Courtesy: XenoFarma

Abundantly, pharmaceutical tablets are processed using a handheld tablet press globally. Immediate and extended release tablets are mostly processed in a handheld tablet press to maintain their effectiveness and quality. The drugs are used for quick and gradual cure of diseases respectively.

Chewable Tablets

Chewable Tablets - Picture Courtesy: PharmaTech

Some of the formulated tablets are difficult of inhale. For this purpose, modern research and development has introduced chewable tablets that are easy to swallow and also have different flavors that can help in their easy intake.

Vitamin Supplements

Vitamax - Picture Courtesy: Nutrifactor

Most of the tablets that contains vitamins or minerals can easily be processed using a handheld tablet press. It ensures their accurate formulation and also helps in saving important material from wastage. Most of the nutraceutical and cosmetics industry use handheld tablet press for processing of vitamins and minerals tablets.

Lozenges

Strepsils Orange With Vitamin C Lozenges - Picture Courtesy: Strepsils

Handheld tablet presses are also compatible with variety of lozenges that are made up of active pharmaceutical ingredients. This equipment can easily produce lozenges medications that are used mostly for throat and mouth diseases that make them easy to swallow or chew.

5.What Is The Working Procedure Of A Handheld Tablet Press?

Handheld Tablet Press Working – Picture Courtesy: Powder Process

A handheld tablet press typically involves following working steps in its operation

Step 1: Formulation

Initially the powdered or granular components are formulated that are to be used for the preparation of a tablet.

Step 2: Material Filling

Once the formulation is done the die cavity of a handheld tablet press is filled with evenly distribution of prepared formulation so that the composition remains the same in each tablet.

Step 3: Compaction

Manual pressure is used to condense the formulation into a tablet shape within the die chamber of a handheld tablet press.

As a result of this pressure the tablet is forms within the die cavity and it is then removed from the die cavity with the ejection mechanism.

Step 4: Tablet Ejection

The tablets are collected to ensure their quality which included their size, shape, weight and consistency. The same process is repeated to continue the process.

6.What Are The Different Types Of Handheld Tablet Press Available Globally?

Globally there are various types of handheld tablet presses available which are used to produce different types of tablets

Single Punch Handheld Tablet Press

Single Punch Handheld Tablet Press

One of the simplest types of a handheld tablet press that only uses a single punch for tablet formulation is a single punch handheld tablet press. A single punch handheld tablet press is used in small scale industries where low productivity volume is present.

Multi Punch Handheld Tablet Press

Hand Operated Multi Punch Tablet Press

A multi punch handheld tablet press is used to produce more than one tablet at a single punch. The presses have multiple turrets and die cavities that rotate to compress the formulation into tablets. A multi punch handheld tablet press is used in small scale pharmaceutical industry to produce to enhance their productivity.

Manual Cam-Operated Handheld Tablet Press

Manual Cam-Operated Single Punch Handheld Tablet Press

A manual cam-operated handheld tablet press is simple to operate and much user friendly as compare to other types of handheld tablet presses. It is ideal for small-scale or for on field applications.

Hydraulic Handheld Tablet Press

Hydraulic Handheld Tablet Press – Picture Courtesy: Global Pharma

A hydraulic handheld tablet press uses hydraulic pressure to provide fine control tablet formation and is perfect for high-speed and large-scale manufacturing processes. This compact press is ideal for producing single tablets.

7.What Are The Main Components Of A Handheld Tablet Press?

The Main Components Of A Handheld Tablet Press

A handheld tablet press has a simple structure consisting of following parts

Die Cavity

The die cavity is the area in which the tablet formulation is entered to form a tablet. Here the punches are squeezed to produce tablets of the specified shape and size.

Punch

A handheld tablet press has two types of punches an upper punch and a lower punch. The upper punch is a part that exerts pressure on the formulation within the die chamber. Whereas the lower punch is the section of press that supports the die chamber and aids in tablet compression.

Handle

A handle is used for manually operating the press and applying pressure to compress the tablet formulation.

Die Holder

In the structure a die holder is that holds the tablet press components including the die cushion and die cavity. It offers stability while the operation is performed.

8.What Are The Major Differences Between A Handheld And A Rotary Tablet Press?

Differences Between A Handheld And A Rotary Tablet Press

Both handheld and rotary tablet press is used for tablet formulation and has same basic mechanism. Some of the differences between these two types of tablet press are:

Description	Handheld Tablet Press	Rotary Tablet Press
Operation	A handheld tablet press has mostly single punch for tablet formation. It uses manual intervention to form different types of tablets. The formulation is entered in the die cavity and pressed manually to form tablet.	Whereas a rotary tablet press uses a turret with multiple die pockets that can compresses the powder or granules into tablets as the turret rotates. Automatic and semi-automatic processes are carried out in an efficient manner.
Machine Structure	A handheld tablet press has a simple and small structure with a handle and a die cavity to press tablet formulation. Manual process is done by the operator in an easier way.	The structure of rotary tablet press is complex as compare to handheld tablet press as it contains multi layered dies, punches and feeding system. All combine to form large number of tablets in a small fraction of time.
Production Capacity	Only 5 to 10 tablets are formed in a minute depending upon the efficiency of the operator.	The rotary tablet press is basically designed in a way that is can fulfill requirement of large-scale industries. Thousands of tablets are produced in a single minute with a greater efficiency and precision.

9.How Different Die Sizes Are Adjusted In A Single Handheld Tablet Press?

Manual Single Punch Tablet Press - Picture Credit: CECLE Machine

Different sizes and shapes of tablet require different dies and punches for their formation. For these tablets, a single handheld tablet press can be suitable by just changing both the upper and lower punches of die cavity. These punches can easily be removed and are interchangeable with other sets. Each die set has its particular size and shape that makes it appropriate to handle and use when required.

Discuss following points are suitable for adjusting punch die in a tablet press:

Die Replacement

Die replacement- Picture Courtesy: Natoli

This is the first thing that comes in mind when talking about adjusting die. Yes you need to replace the whole die with older one. This is involved with manual removal of die by twisting the mold followed by newer die changeover.

Adjusting Lower Punch

Lower Punch of tablet Press

Many handheld tablets press are featuring adjustable lower punch with variation in thickness and diameter. This is the most flexible way as this is fast and easy.

Turret Rotation

Turret Rotation

By rotating turret, die of different sizes can be adjusted and allows a quick changeover.

Modern tablet presses are featured with tool free adjustments of dies with high working efficiency.

10.What Are the Major Differences Between A Handheld And An Automatic Tablet Press?

Some of the major differences between handheld and automatic tablet press are:

Parameter	Handheld Tablet Press	Automatic Tablet Press
Working Operation	Complete operation in a handheld tablet press required manual intervention that is to perform all tasks. From material loading to ejection of tablet, all of the process is done manually.	In an automatic tablet press, majority of the process steps are performed by the machine itself. The machine gets the material from the hopper or container, presses it in between die cavities and then ejects them out of the system once they are fully prepared.
Controlling	From adjustments of die to production of tablets, the operator is responsible for the controlling of a handheld tablet press.	Machine is responsible for the task performing whereas the system parameters like speed, dispensing time, flow and other are feed by the operator that are used in controlling the operation.
Efficiency	The overall efficiency of a handheld tablet press remains low and completely relies of the expertise of the concern operator.	Where an automatic tablet press has complete automatic processes, the overall efficiency of the system remain top the mark in each of the produced tablet. Completely aligned and synchronized production is carried throughout the operation.
Productivity	The productivity of a handheld tablet press remains very low as it depends on the performance of operator that supports small scale industries only.	High level large scale industries prefer automatic tablet press where the production requirement remains high. These machines can produce thousands of tablets in an hour.

11.How To Maintain A Handheld Tablet Press?

How To Maintain Handheld Tablet Press

Lubrication

To maintain a handheld tablet press it is important to lubricate its moving part with oil or grease that makes it easy to move for a longer period. If lubrication is not done on proper basis it can damage the parts both internally and externally.

Cleaning

One of the most important ways to maintain a handheld tablet press is to clean it properly after every batch or designated duration. As tablet powder can remain left in the die cavity therefore it is necessary to clean it properly and regularly to maintain the efficiency of tablets. Formulation and composition of tablets can also get affect if it is not cleaned properly.

Calibration Of Die Cavities

With certain pressure, die cavities or punches of a handheld tablet press can transform its shape that can be dangerous sometimes. It is always necessary to check the dimension of these punches and die cavity to maintain the quality and shape of any tablet. Otherwise, it can create a greater loss to the manufacturer.

Conclusion

A handheld tablet press gives significant usage when it comes to tablet formation and R&D purpose. It is always important to understand the uses, advantages, and operational methods of a handheld tablet press before buying it. Allpack is always here to provide you complete information related to a handheld tablet press and helps you in buying the best type of press. For any query contact our customer representatives that are available 24/7 for your guidance.

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Carton Forming Machine: The Complete Buying Guide in 2024

Honey Packing Machine

Carton Forming Machine: The Complete Buying Guide in 2024

Packaging cartons are important in keeping the inner products safe and secure. In addition to the cartoning machine in industrial packaging, the machine that makes cartons is a carton forming machine. Boxing products are important for their protection and here is where carton forming machine comes into play.

It is more popular than carton forming manually because of its accuracy, precision and flawless caron forming. Packaging is a challenging task if performed by hand but modern science has innovated carton forming machine that is way speedier than a simple hand.

So, if are you keen on adding this handy machine to your production and are interested in discovering more about this useful machine then read through this to learn features, benefits, working, and much more about carton forming machine

Add a header to begin generating the table of contents

1.How To Define Carton Forming Machine?

Carton Forming Machine

A carton forming machine also called a carton erecter or a carton former is a machine that takes blank chipboard, cardboard, corrugated banks or paperboard and erects, folds, and seals it into a carton. Its primary function is to form cartons that are with or without upper covering.

It is a servo-driven machine that forms and seals cartons using a lock mechanism. It also seals cartons with glue, tape, or adhesive. It is designed for achieving high speed, is versatile in its processing and easily handles a complete range of blanks. It is seamlessly integrated into the packaging line for streamlined operation.

2.What are the Useful Benefits of Carton Forming Machine?

Carton forming is added to the production because of its adaptability and fast processing. Some of the important benefits of this machine are:

Automation

Automation of Carton Forming Machine- Picture Courtesy: Fipal Srl

A carton forming machine is composed of different mechanical and computerized systems that automate the process of forming a carton. With its automation, it can make numerous cartons per minute. Automation of the carton forming machine translates to high productivity that is related to more profits.

Cost-Cutting

Cost cutting with Carton Forming Machine

With its automation, it also cuts down the need for human intervention and manual labour. This in turn lowers the labor wages saving operation costs. Moreover, with this machine, there is less chance of material wastage which leads to reduced material purchase and saves the packaging budget.

Consistent Performance

Consistent Performance of Carton Forming Machine- Picture Courtesy: SiroSilo Industrial

Carton forming machine has no variation from batch to batch and each time it produces cartons of the same size, design, and, dimensions. These cartons do not have even a minute difference in their structural composition and that leads to consistency in the secondary packaging. This uniform quality of cartons is vital in protecting the goods and in upholding a professional look.

Customization

Customization of Carton Forming Machine- Picture Courtesy: Pixartprinting

A carton forming machine is a flexible and versatile machine that is easily customized to create different carton types according to production packaging requirements. This machine is tailored to fabricate a wide range of cartons with easy and quick adjustments to machine parts. This versatility of the carton forming machine is important for businesses producing multiple cartons.

Increased Safety

Safety Emergency Stop Button- Picture Courtesy: Quisure

Fulfilling industrial safety guidelines is a must for manufacturing lines to prevent workplace accidents. A carton forming machine has different features like fireproof electric cabinets, safety enclosures, alarm systems, buzzers, and safety stop buttons for the safety of the operator and the workplace.

3.Where Carton Forming Machine is Used?

A carton forming machine is used in every far and wide industry because of its accurate and precise working and adaptability. Here is a list of some important industries in which a carton forming machine is utilized:

Food Industry

Use of Carton Forming Machine in Food Industry- Picture Courtesy: Pixartprinting

In the food industry, different types of boxes and trays are used for secondary packaging of food pouches, bags, clamshells, bottles, jars, and tins. It also creates trays and boxes for packaging fast foods and ready-made meals.

Beverage Industry

Use of Carton Forming Machine in Beverage Industry- Picture Courtesy: Packaging Strategies

A carton forming machine has a significant contribution to the beverage industry as it creates cartons for storing various sodas, juices, oils, smoothies, drink mixes, alcoholic beverages, water, and many more. Its seamless processivity is what makes it important in the beverage industry.

Pharmaceutical Industry

Use of Carton Forming Machine in Pharmaceutical Industry- Picture Courtesy: CPHI Online

A carton forming machine has a prime place in the pharmaceutical industry for packing blisters, syringes, ampoules, vials, etc. This machine fabricates different carton types like external flap cartons, trays, regular slotted cartons, and many more in the pharmaceutical industry.

Cosmetic Industry

Use of Carton Forming Machine in Cosmetic Industry- Picture Courtesy: Sufio

Due to its knack for creating beautiful and captivating cosmetic cartons, this machine has prominence in the cosmetic industry. It creates secondary packaging cartons for cosmetic lotion bottles, foundation tubes, cream jars, lipsticks, and many more.

Chemical Industry

Use of Carton Forming Machine in Chemical Industry- Picture Courtesy: Storemasta Blog

Chemical products need sturdy and leakproof packaging for their containment and hence, carton forming machine is a vital part of the chemical industry. It creates strong and durable cartons for shipping and retailing chemicals.

Textile Industry

Use of Carton Forming Machine in Textile Industry- Picture Courtesy: Canpak Packaging

Different cloths, fabrics, threads, and fashion accessories are transported in tough and strong cartons. Therefore, carton forming machine is utilized in the textile industry for erecting and forming robust containers that can easily handle heavier textile loads.

Electronic Industry

Use of Carton Forming Machine in Electronic Industry- Picture Courtesy: NetPak

This machine is needed in the electronic industry for packaging different flashlights, equipment, bulbs, fans, etc. in tough and durable boxes. This machine is a high-speed instrument used for the correct packaging of electronic goods.

4.What are the Primary Parts of a Carton Forming Machine?

Various parts of the carton forming machine carry out their specific role in harmony to ensure the steady performance of the carton forming machine. these parts are discussed below for your understanding:

Parts of Carton Forming Machine- Picture Courtesy: SiroSilo Industrial

Vacuum Sucker	This part of the carton forming machine picks up the blank carton sheet from the blank magazine using suction force and holds them without damaging these sheets during succeeding carton forming steps.
Press Plate Height Adjustment	It consists of screws and knobs that assist in adjusting the height of the press plate. It is a mechanism that helps deliver accurate pressure force to the flaps of the carton.
Blank Retainer	During the folding and gluing step, the blank retainer parts grip securely the blank sheets using clamps and rollers. It is essential in the precise folding of sheets and the application of glue to carton sides. It is composed of clamps, rollers, etc.
Touch Screen HMI	It is an intuitive display panel that is present in most carton forming machines. Using this HMI touch screen, the operator programs and supervises the equipment. Furthermore, it outputs troubleshooting instructions in case of machine failure.
Protective Glass	It is a clear glass cover surrounding the machine that prevents operators from unintentionally gaining access to the carton forming machine.
Power Switch	This is the main switch for powering the carton forming machine.
Case Height Adjustment	It is a system that fix the height of the forming section to accommodate cartons of different sizes and designs.
Press Plate	It is used for applying pressure to the carton sides to create a strong bond between them. It is present above the side belt part and is vital in giving the carton box its shape.
Blank Magazine	This is the part where large quantities of cardboard or other material sheets are placed before the operation.
Air inlet	It is an inlet through which compressed air enters the carton forming machine and is rudimentary in working vacuum sucker.
Side Belt Width Adjustment	This part of the carton forming machine adjusts the width of side belts which allows for an accurate transport of blanks to the forming station.
Electric Cabinet	Different kinds of switches, relays, power cables, and small wires are enclosed in the durable electric cabinet. This section of the machine is essential in powering its different components.
Emergency Stop	It is a red-colored knob present on the control panel. It is pressed to instantly stop the machine in case of a hazardous situation.
Foot Pad	It is a foot support that absorbs any shock or vibration that occurs while the machine is in operation. It supports and stabilizes the carton forming machine.
Side Belt	It is the part that transports the blank sheets to the forming machine. It is essential in the proper alignment of the cardboard sheets.

5.What are Different Kinds of Carton Forming Machines?

A carton forming machine is classified into different types depending on the automation and carton styles. Here is a detail of the classification of a carton forming machine.

According to Automation

Semi-automatic Carton Forming Machine

Semi-automatic Carton Forming Machine- Picture Courtesy: Fallsdell

It is a compact-sized machine that carries out its functioning with the help of an operator. The blank cardboard or other materials are manually loaded on the blank magazine. Forming, pressing, and gluing are performed independently by the machine.

Its productivity is low; hence, it is best suited for small-scale operations. It is quite budget-friendly so preferred choice for small enterprises.

Automatic Carton Forming Machine

High Speed Automatic Carton Forming Machine

It comes with an integrated blank magazine and sometimes robotic systems that automatically lift and load the blank magazine. Forming, pressing, and unloading are carried out autonomously by the machine with its mechanical and computerized controls.

It has higher productivity; therefore, more suited to larger businesses. It requires a high initial investment and a larger operating room.

According to Box Type

Regular Slotted Carton Forming Machine

Regular Slotted Carton Forming Machine

It is the most frequently used carton forming machine because it outputs a popular box style which is a regular slotted carton. Regular slotted carton forming machine forms cartons from a single blank that has prescored flaps.

The working of this machine is straightforward and it is easy to operate. However, it does not accommodate intricate box shapes.

Tray Carton Forming Machine

Tray Carton Forming Machine- Picture Courtesy: Wayne Automation

This machine folds and prepares a tray-like box that does not have an upper lid. This tray is used for the delivery of pre-made meals. It is a versatile machine that is capable of creating all kinds of standard tray boxes.

It is not suited for creating closed boxes.

Tuck Top Carton Forming Machine

Tuck Top Carton Forming Machine- Picture Courtesy: SiroSilo Industrial

It folds and creates a top tuck carton using pre-folded top sides. It is a cost-effective machine because it does not use tape or glue to close the box. It creates secure closure boxes that are ideal for faster packaging of products.

Nevertheless, this machine requires specialized parts for forming tuck-top cartons.

6.What is the Working Principle of Carton Forming Machine?

Steps of carton Forming Machine

The working of the carton forming machine is divided into different steps, and each is carried out flawlessly to convert blanks into cartons. The details of these steps are given below:

Blank Loading

Blank Loading

Initially, a large stack of flat sheets is loaded inside the bag magazine by the operator or by the robotic arm. It is stored in the loading area or bag magazine for continuous carton forming.

Vacuum Sucking and Alignment

Vacuum Sucking and Alignment

Sheets are positioned in the right orientation by the vacuum sucker. This part of the carton forming machine picks up the blank and carries it to the forming station. It creates a suction force by which blanks move to subsequent processing stations.

Folding and Forming

Folding and Forming

In the forming station, different mechanical arms, belts, and clamps are present that fold the blank sheets along the pre-scored lines. These devices mould and transform the blank sheets into the desired configuration carton box by folding its top, bottom and side seams.

Gluing and Sealing

Gluing and Sealing- Picture Courtesy: Fipal Srl

After forming, the glue or sealing tapes are applied at some areas of folded seams to tightly secure these folds of the formed carton. The flaps are secured shut and tightly closed using heat, pressure or other techniques.

Ejection

Carton Ejection

After successful forming and sealing, the formed carton is ejected from the machine via a conveyor belt. The ejection system present in the carton forming machine allows for the smooth removal of formed cartons from the machine.

7.What Carton Materials are Processed by the Carton Forming Machine?

A carton forming machine is a versatile piece of equipment, that processes different types of carton materials. Some of the important materials are detailed below:

Corrugated Cardboard

Corrugated Cardboard

It is one of the most frequently used carton materials. It has three layers- two flat layers and one sandwich fluted layer. It is a versatile material used for packaging diverse products. It is notorious for its excellent toughness and cushioning effect.

Cardboard

Cardboard- Picture Courtesy: Zart Art

A carton forming machine routinely processes cardboard for making trays and tuck top cartons. Cardboard is a heavy-duty paperboard material that is easily printed. It is known for its rigidity.

Paperboard

Paperboard- Picture Courtesy: Design Packaging and Tape

It is another common material handled by a carton forming machine. It is a thick paper-based material and is often used for its added strength, lightweight, and high printing qualities. It is typically utilized for making folding cartons.

Chipboard

Chipboard

Wooden-based chipboard is also processed by the carton forming machine. It is also termed as particleboard. It has less weight than paperboard. It has a smooth finish, resulting in aesthetically pleasing cartons.

Kraftboard

Kraftboard

It is a brown colour paper board that is tough. It is gaining traction for its eco-friendliness because it is easily recycled.

8.What Carton Boxes are Formed by Carton Forming Machine?

Carton forming machine forms diverse kinds of carton boxes that are listed below:

Slotted Cartons

There are two types of slotted cartons formed by the carton forming machine:

Regular Slotted Cartons

Regular Slotted Cartons

It is one of the most popular styles of cartons that contain pre-scored flaps. It is a robust carton, typically employed in secondary packaging and shipping of goods.

Half-slotted Carton

Half-slotted Cartons- Picture Courtesy: Atlas Container

It is similar in structure to a regular slotted carton but it features short upper flaps that join in the center. It provides easy access to cartons from the top.

Folding Cartons

Carton forming machine forms numerous styled folding carton boxes such as:

4 Corner Box

4 Corner Box- Picture Courtesy: Emenac Packaging

It contains four pre-glued flaps that fabricate the sides and bottom of the box upon folding. It has a collapsable hinge over its top.

6 Corner Box

6 Corner Box- Picture Courtesy: BlueBox Packaging

It has 6 pre-glued flaps that make an upper lid and a bottom base. It is a sturdy, protective, and durable packaging solution.

Top Tuck Carton Box

Top Tuck Box- Picture Courtesy: Imperial Paper

It is a one-piece cardboard carton created from pre-folded flaps. Unlike 4 corner tox, the flaps of the top tuck carton fold at the inner side and go under the top part, thus forming a more secure seal.

Trays

Carton forming machine is also employed for forming tray boxes like:

4 Corner Tray 4 Corner Tray	These trays have 4 pre-folded flaps and are either tucked inward or outward. It offers more support when used for packaging heavier objects.
Trays with Lids Tray with Lids- Picture Courtesy: beepap.com	As the name, this kind of carton tray comes with an upper lid. It packs products for display purposes. It has pre-folded-flaps similar to 4 corner trays.
Clamshell Tray Clamshell Tray- Picture Courtesy: Deli Supplies	It has a structure similar to a clamshell with two hinges. It is formed by paperboard or cardboard and is a more secure and eco-friendly packaging unit.
Take-way Tray Take-way Tray	It has numerous pre-folded flaps that are folded to create a takeaway tray. It is often seen in take-way delivery.

9.What Options Are Available for Carton Sealing in Carton Forming Machine?

There are wide variety of carton sealing options in the carton forming machine. These sealing options result in the secure closing of carton flaps. Here is a list of important sealing options:

Cold Glue Sealing

Cartons Sealed by Cold Glue- Picture Courtesy: Gateway Packaging

Cold glue that is liquid at room temperature is applied to the flaps of the carton to create a strong bond between cartons. It does not need any heat, saving utility bills. However, it takes more time to dry and is suited to particular carton materials.

Hot Glue Sealing

Carton Sealed by Hot Melt Glue

The glue solid at room temperature is melted and then applied to the seams of the carton. This glue quickly dries, thus increasing processivity. However, it requires heat consequently, it is not budget-friendly.

Stapler Sealing

Stapled Carton

The stapler pin is used for sealing carton boxes. This type of sealing uses a stapler for closing the flaps of the carton. This sealing is popular because of its high efficiency, speed, and cost-effectivity. However, it does not create a strong bond between flaps as formed by glue.

Pressure-Lock Sealing

Pressure-lock Cartons- Picture Courtesy: Netpak

Some carton flaps have an interlocking seal that closes via pressure. It is more cost-effective, as there is no need for glue and stapler. It creates a secure sealing but is suitable for some carton boxes.

Tape Sealing

Taped Carton

Packaging tape is also used for closing the flap of a carton in some carton forming machines. It is a fast and easy way to seal the cartons.

10.What are the Add-on Features of Carton Forming Machine?

Some useful features of a carton forming machine that increase its efficiency, productivity, and consistency are:

Robotic Arm

Robotic Arm

This mechanical part can be added to the carton forming machine to eliminate the need for manual stacking of blanks in the blank magazine. This robotic arm easily lifts heavier loads and places them in the loading area.

Printers

Printed Carton Box- Picture Courtesy: Printo

Inkjet or thermal transfer printers can be integrated into the carton forming machine to label cartons with safety instructions, logos, serial number batch number, product name, business information and other related information.

Gluing Units

Carton Gluing Station- Picture Courtesy: SBL Machinery

These parts apply hot melt and cold glue for fast and effective bonding between the flaps. This unit can be easily adjusted to smear glue on different carton types.

Handles and Window Adding Stations

Carton with Handles and Window- Picture Courtesy: Superbox

This unit adds handles and other carry-on cartons for ease of carrying. Moreover, another unit adds a small clear window on the carton for viewing the inside product.

11.How To Maintain the Carton Forming Machine?

Carton Forming Machine

Maintaining is a sure way to increase the operational capacity of a carton forming machine and regular maintenance will keep the machine healthy for a long time. The maintenance schedule of carton forming machine is:

Daily Maintenance	Using a damp cloth, wipe down the exterior and interior of the machine to get rid of dust and other product buildup. Use soapy water to clear the glue applicator area. Use detergent water to open clogged glue nozzles. Check the levels of glue and refill them if required. Lubricate all rollers, screws, and other mobile parts. Check for loose nuts and screws and tighten them if needed.
Weekly Maintenance	Perform deep cleaning using cleaning agents. Check for wear and tear in seals and gaskets. Inspect the working order of sensors and recalibrate if needed.
Monthly Maintenance	Inspect wear and tear in the electric component. Tight any loose cables and wires. Check the working order of safety systems like buzzers, emergency stop buttons, alarm systems, lights, etc.
Yearly Maintenance	Conduct a thorough examination of the machine. Check for defects in any part and replace them if needed.

12.What are Technical Problems and Their Troubleshooting in the Carton Forming Machine?

Even though a carton forming machine is a sophisticated unit, it is still prone to occasional problems. These problems could cause production delays and result in loss of productive time and money. However, with some tips and tricks, these problems are easily resolved, for instance:

Cause

Solution

Picture

Jamming in Machine

Improper alignment of blanks

Old or defective roller

Misalignment of rollers

Buildup of glue or other adhesives

Poor vacuum suction force

Inspect and realign blanks in proper configuration

Replace old roller

Realign machine roller

Clean and remove glue or other adhesives

Check and reprogram vacuum settings

Jamming in Machine- Picture Courtesy: star-parker.com

Failure in Glue Application

Glue spraying nozzles are clogged.

Low level of glue at the gluing station

Defective pumps

Properly clean glue spraying nozzles

Refill glue

Repair pumps

Failure in Glue Application- Picture Courtesy: Machineseeker

Over-heating of the Machine

Ventilation filters are not cleaned properly.

Old or damaged bearings

High friction in the machine

Electric overloading

Properly clean the ventilation filters

Replace worn-out bearings

Lubricate the moving parts

Inspect electric overloading and shut down the machine if necessary

Over-heating of the Machine- Picture Courtesy: Hillside Custom

Improper Formation of Cartons

Poor quality glue

Insufficient glue quantity

Defective forming systems

Old molding system

Improper positioning of the sensor

Check the quality of glue and replace it.

Apply an accurate amount of glue

Repair and calibrate the forming section

Replace old moulds

Fix the positioning of the sensor

Improper Formation of Cartons- Picture Courtesy: New Products and Trends in Industry

Conclusion

A carton forming machine comes with a wide range of benefits and gives a boost to production. Accuracy, consistency, protection, and speed are a few features that make the carton forming machine popular in industries. Hopefully, by reading this guide, you have learnt about vital elements of the carton forming machine and now you can select the best carton forming machine for your businesses quite easily. Want to learn more about carton forming machine? Then click on the main Allpack website.

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Want to get Best Price Carton Forming Machine from China?

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Carton Forming Machine: The Complete Buying Guide in 2024 Read More »