Tablet Compression Machine: The Complete Buying Guide In 2023

1. What Is A Tablet Compression Machine?

Tablet compression machines are basically pharmaceutical equipment that is used to compress powdered or granular materials into pills or tablets. The process of a tablet compression machine includes compressing material under a much higher pressure to form a solid formed tablet. This tablet can then be further coated or packaged for distribution to consumers.

Tablet compression machines mostly consist of a hopper or feeder for the material, a compression chamber or die that shapes the tablet, and a mechanism that compresses the material into the desired form.

2. What Materials Can Be Compressed Using A Tablet Compression Machine?

The following materials are mostly compressed using a tablet compression machine

• Drug Powders

Powders that are used to make drugs are the simplest application of tablet compression machines. This includes active pharmaceutical ingredients (APIs) and excipients that are usually present in every type of pharmaceutical industry.

• Granular Materials

These materials are made up of small particles and can include APIs and excipients. Granular requires a high level of expertise when compressed using a tablet compression machine. Methylcellulose granules and other primary granules are examples of some granules used in the pharmaceutical industry.

3. What Shapes Of Tablets Can Be Produced By A Tablet Compression Machine?

Tablet compression machines can produce different types of shapes for tablets depending on the structure of the machine and the shape of the die. Some of the most common tablet shapes are

• Round Tablets

Round tablets are the most common tablet shape found in every part of the world. This type of shape can easily be produced using a tablet compression machine as the die structure is not much complex.

• Oblong Tablet

This type of tablet is elongated tablet with rounded edges on both sides. Oblong tablets are compressed using a tablet compression machine.

• Oval Tablets

Oval-shaped tablets are much similar to oblong tablets but are more sharped oval in shape from both edges.

• Square Tablets

The square shape of these shapes of the tablet is with straight edges and can be used for chewable or sublingual medications.

• Triangular Tablets

Triangular type tablets are not typically found everywhere in the world. These tablets are tablets with three sides and can be used for sublingual medications.

• Diamond Tablets

Diamond tablets are tablets are with four sides like a diamond shape and their dies are also available for a tablet compression machine

• Custom Shapes

Some of the tablet compression machines also allow for custom shapes to be created. These customized tablets can be used for branding or to make the tablet easier to swallow as per these usages.

The choice of tablet shape depends on a variety of factors, including the medication’s intended use, ease of swallowing, branding, and manufacturing capabilities.

4. What Are The Applications Of A Tablet Compression Machine?

 Here are some of the most common applications of a tablet compression machine

• Pharmaceutical Industry

Pharmaceutical industry uses tablet compression machines as human-saving drug and requires high level of synchronization and care. A tablet compression machine compresses a tablet in a way that its chemical composition remains the same and makes it easier for further packaging and shipping stages.

• Cosmetics Industry

Tablet compression machines can be in the cosmetics industry to produce tablets that are used as cosmetics and applied for curing the human body. Vitamins or dietary supplements are some examples that are compressed using a tablet compression machine.

• Agricultural and Veterinary Chemicals

Tablet compression machines are also used to produce tablets for agricultural chemicals such as pesticides or fertilizers.

Tablet compression machines produce tablets for veterinary medicine like medication for pets.

• Food and Confectionery 

Tablet compression machines are also used to make tablets or pills for food and confectionery industry. Products like C value mints or vitamin supplements are made using a tablet compression machine.

Other than this various types of candy tablets, breath fresh mints, vitamins and minerals nutritional supplements, protein bars, energy bars, chewing gums and antacids are some of the food and confectionery products produced using a tablet compression machine.

5. What Are The Advantages Of A Tablet Compression Machine?

Some of the key advantages of a tablet compression machine are

• Unique Punches

Unique and special types of punches are present in a tablet compression machine that compresses the powder or granular material into tablets and push them out of the die system.

• Dust Extraction System

Dust extraction system reduced the risk of contamination within the system. These are used to remove excess powder or granular material from the compression chamber and make the machine an efficient one.

• Consistent Quality

Tablet compression machines are used to produce tablets that are uniform in size, shape, and weight. This advantage of a tablet compression machine ensures consistent quality and dosage.

• High Efficiency and Precision

Even in mass products, tablet compression machines produce a large number of tablets in an efficient and quick manner. The quality of tablets remains the same and is not affected at any stage. These machines can also accurately control the number of active ingredients in each tablet and ensure precise dosing.

• Hygienic  

With a feature of easy cleaning and maintenance, a tablet compression machine gives high level of hygienic products and reduces the risk of contamination.

6. What AreThe Working Principles Of the Tablet Compression Machine?

Working Principle Of Single Punch Tablet Compression Machine

• Initially the powder for tablet is fed into the single punch tablet compression machine through the loading cup or feeder.
• Once is the feeding is done, the excess material is removed from the surface of die and ensures that free movement of die to be performed.
• The upper punch of the single punch tablet compression machine is forcefully moved downward with the help of a hand crank handle and it compresses the particles inside the die.
• The upper punch is then moved backward to its original position in the fourth stage and the lower one ejects the tablet formed.
• Here the cycle gets completed at the tablet is removed from a single punch tablet compression machine. The same process is repeated at every interval.

Working Principle Of Rotary Tablet Compression Machine

• The powder is first fed into the hopper which is located above the feeding mechanism. The feeding mechanism is responsible for the traveling of powder from the machine to the die cavity.
• As the material reaches the die cavity a pre-compression process is there. The first station of the machine compresses the powder in the die cavity to a low-density slug. This slug is then transferred to the next station.
• After the pre-compression, the main compression indulges the high pressure punches compress the slug into a tablet of the desired size and shape. The punches are arranged on a turret that rotates continuously and aligning the die cavity with each punch in turn.
• The force applied by the punches is controlled by adjusting the compression depth and the dwell time. After compression, the punch retracts and the tablet is ejected from the die cavity. The turret then rotates to align the next die cavity with the punch and the process repeats.
• The tablets are collected in a container and can then be coated or packaged for smooth travelling.

7. What Are The Main Components Of Tablet Compression Machines?

Main Components Of Single Punch Tablet Compression Machine

• Hand Crank Handle

The hand-wheel handle is used to manually rotate the turret of the tablet compression machine. This allows the operator to position the punch and die set in the correct position for tablet compression.

• Loading Cup

The filling or loading cup is a component of the machine used to hold the granules or powder mixture that is to be compressed into a tablet. The filling cup is located above the die cavity and is used to deliver the granules or powder mixture into the die cavity.

• Outlet

The outlet is where the compressed tablets are discharged after the compression process is complete. The outlet is designed to guide the tablets into a container or onto a conveyor belt.

• Motor

The motor is the power source that drives the compression process. The motor provides the energy needed to compress the granules or powder mixture into a tablet.

• Belt

The belt is a component of the machine that connects the motor to the turret. The belt transfers the power from the motor to the turret, which rotates the punch and dies set.

• Button

The button is used to activate or deactivate the motor. Ans it is typically located on a control panel that also includes other settings and adjustments for the machine.

• Safety Mask

A safety mask is a protection device that covers the compression zone of the machine. It prevents the operators from coming into contact with moving parts and potentially getting injured during the compression process.

• Driving Belt

Driving belt transmits power from the motor to the compression tooling. Driving belt is responsible for ensuring that the tooling rotations are at the required speed for compressing the powder or granular material into a tablet.

• Base

The base of the tablet compression machine is its foundation that supports the other parts of the machine.

• Pressure Regulation

Pressure regulation ensures that the tablets produced are of consistent quality and meet the required specifications. The pressure regulation system consists of a series of adjustable knobs or dials that allow the operator to fine-tune the compression force applied to the material being compressed.

Main Components Of Rotary Tablet Compression Machine

• Hopper

A hopper holds the powder or granules that have to be compressed into tablets. All the material is initially filled in this container and then fed in to the system. 

• Organic Glass

The organic glass is a transparent cover that encloses the compression zone of the machine allowing the operator to see the compression process as it occurs. This helps the operator monitor the tablet production process and detect any issues that may arise.

• Rotary Table

The rotary table is the place where complete rotary tablet compression process takes place. It contains the dies, punches and other major parts of machine.

• Adjusting Handle

The adjusting handle is a control mechanism that adjusts the tablet compression force which is necessary to produce tablets of consistent size and weight. The operator can adjust the handle to increase or decrease the compression force that affects the density and hardness of the tablets.

• Discharge Port

The discharge port is an opening on the side of the machine where the finished tablets are ejected from the compression zone. The tablets are collected and can then be packaged for distribution.

• Operation Panel

 The operation panel is the user interface platform of a tablet compression machine which allows the operator to set and adjust the compression force, tablet size and other parameters.

• Danger Button

 Danger button is applied to shut the power off in an emergency or hazardous situation. The danger button is usually on the body of machine and is easily accessible to the operator.

• Power Plug

Power plug connects the machine to a power source. It is usually located at the back or bottom of the machine and is plugged into a power outlet or socket to provide electrical power to the machine.

• Electric Appliance Box

Electric appliance box contains electrical components of a tablet compression machine. Motors, wiring and other electronic controls are some of the electrical appliances present in a tablet compression machine.

• Stainless Steel

Stainless steel is a type of metal that is commonly used in the manufacturing of tablet compression machines due to its durability, ease of cleaning and resistance to corrosion.

8. What Is The Turret By A Tablet Compression Machine?

• Structure Of Turret

A turret is a circular disc that is mounted on the upper part of the machine and rotates around a central axis in a tablet compression machine. The turret comprises of multiple die pockets and each die pocket is designed in a way that it holds a set of upper and lower punches.

A number of die pockets in a turret depends on the size and type of tablet compression machine. Mostly a turret holds 12 to 100 die pockets depending on the size of the machine.

• Working Process

The continuous rotation of turret during the compression process allows each die pocket to fill, compress, and then eject the tablet in a sequential and automated process. Once the tablet is formed, the lower punches eject the tablet and the upper punches return to their initial position.

The precise and timely action of a turret ensures that each die pocket is filled and compressed accurately. Turret gives same weight, size, and shaped tablet efficiently.

9. What Types Of Tablet Compression Machines Are There?

Tablet compression machines are designed in a specific manner to meet production needs and requirements. The main types of a tablet compression machines are

• Single Punch Tablet Compression Machine

This is the simplest type of tablet compression machine that uses a single punch to compress the powder into tablets. Single punch tablet compression machines are mostly used in small-scale industries where the volume of production is very low. 

• Rotary Tablet Compression Machine

A rotary tablet compression machine is one of the high-speed tablet compression machines that can produce thousands of tablets per minute. It uses turret with multiple die pockets and the tablets are compressed once the turret rotates. 

• High-Speed Rotary Tablet Press Machine

A high-speed rotary tablet press is a type of tablet compression machine that produces tablets at a high speed. The machine has a turret that rotates at a high speed, and punches that compress the powder or granules into tablets.

The machine can produce a large number of tablets in a short amount of time, making it suitable for large-scale production. The high-speed rotary tablet press can also produce tablets of different shapes and sizes, depending on the design of the punches and dies used.

• Multi Layer Rotary Tablet Press Machine

A multi-layer rotary tablet press machine is a type of tablet compression machine that can produce tablets with multiple layers. The machine has multiple turrets that rotate at different speeds, and punches that compress the powder or granules into tablets.

The machine can produce tablets with different colors, flavors, or active ingredients in each layer, which makes it suitable for producing multi-layer tablets. The multi-layer rotary tablet press machine is often used in the pharmaceutical industry to produce controlled-release tablets or tablets with different release rates for different layers.

10. What Are The Differences Between Single Punch Tablet Press And Rotary Tablet Press?

Both of the machines follow basic same operation but the main differences between the two types of machines are

• Working Principle

Single-punch tablet press uses only a single punch to compress the powder or granules into a tablet.

Rotary tablet press uses a turret with multiple die pockets that can compress the powder or granules into tablets as the turret rotates.

• Machine Structure

A single punch tablet compression machine is characterized by a small desktop electric continuous tablet pressing machine that can also be operated by hand.

The extruded tablets have an average thickness and high gloss without polishing. Because the single-punch tablet press has only one pair of dies, it is called a single-punch tablet press.

The structure of rotary tablet compression machine is quite complex as compared to single punch tablet compression machine. A proper mechanism containing multi layered dies, punches and feeding system is present in a rotary tablet compression machine.

• Production Capacity

A single punch tablet press is suitable for small-scale production and is used to produce only a few hundred tablets per hour. The maximum productivity achieved using a single punch tablet compression machine is around 5 to 10 tablets per minute.

The rotary tablet press is designed for large-scale production setups and has the ability to produce thousands of tablets per minute. More than a hundred tablets are produced in a minute using a rotary tablet compression machine with an efficiency of 95 to 99%.

11. How Does Tablet Weight Controlled By A Tablet Compression Machine?

The weight of a tablet is an essential parameter that needs to be controlled during the tablet compression process.

• Powder Feeder

The most important thing that affects the weight of the tablet is the powder feeder mechanism. To control the amount of powder or granules that are to be fed into the die cavity.

• Die Filling System

The cavity of die should be filled uniformly and consistently to ensure that the tablets have the same weight. To achieve accurate weight of tablet, the die-filling system uses a dosing disk or a scraper blade to level the powder and resulting consistent filling volume.

• Compression Force

The compression force should be adjusted and monitored properly to ensure that the tablet weight is within the required specifications.

• Ejection Method

The ejection mechanism ejects the prepared tablet out from the die cavity after compression. The ejection system should be controlled to ensure uniform and consistent ejection of tablets from the system without causing any damage to its formation.

12. What Are The Auxiliary Equipment For A Tablet Compression Machine?

There are several types of auxiliary equipment that are commonly used with tablet compression machines in the pharmaceutical industry. These include

• Dust Extractor

Dust extractors are used to extract dust and debris from the tablet compression machine during the compression process. The dust extractor helps to maintain a clean and safe working environment for the operators and also helps to prevent cross-contamination between different batches of tablets.

• Tablet Deduster and Metal Detector

A tablet deduster removes excess powder or debris from the surface of the tablets after they are compressed. The tablet deduster ensures that the tablets have a clean and smooth surface which is important for accurate packaging and labeling of the tablets.

Metal detectors are also present with a tablet deduster in tablet compression machines that are used to detect and remove metallic contaminants if any are present in the tablet.

• Tablet Coating Machine

After formation of compressed tablets, some machines incorporate tablet coating machine for applying coating onto the surface of the tablets. The coatings are used for protecting the tablet from moisture, masking the taste of the medication and improving the appearance of the tablet.

Conclusion

Tablet compression machines are one of the unique types of machines used to compress and form different types of tablets. With the advancement in technology, world is now developing new techniques in every field. For better tablet compressing and forming, Allpack China provides you with numerous options related to tablet compression machines. If you still find any query contact our customer service centers or visit our website https://www.allpackchina.com/.