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Xinghua Xianghe Pharmaceutical Machinery Co., Ltd
What factors should be considered when selecting a tablet press?
Date: 2023-10-27Read: 0
What factors should be considered when selecting a tablet press?
(1) The variety, grade, and added value of the products produced. If the tablet press manufacturer produces a good variety of products with high added value, they can choose high-end equipment. After all, such equipment has good performance, high degree of automation, and can ensure product quality;
(2) The size of production. When selecting equipment, it is not necessary to blindly pursue the output of a single machine, but to determine the required single machine output of the equipment based on the actual production demand of the shift;
(3) Economic affordability. Tablet press manufacturers generally have certain advantages in the application of advanced technology, equipment stability, process control, and the guarantee of final product quality for joint ventures and imported tablet presses. However, the price is 5-6 times or even higher than that of domestic equipment with the same production capacity, which depends on the economic affordability of the equipment manufacturers;
(3) The floor area of the workshop. If the layout of the workshop is relatively spacious in terms of area, medium and low-speed tablet presses can be selected. The number of tablet press manufacturers' equipment can be appropriately increased, which can reduce equipment investment. If the equipment layout in the workshop is tight, sub high speed or high-speed tablet presses can be selected. Although this requires a higher investment, it avoids the difficulties in equipment layout. Regardless of whether the area is large or small, the author believes that in general, it is advisable to install at least 2 tablet presses. This can avoid the occurrence of production line shutdown when the tablet press malfunctions.
In recent years, many tablet manufacturers have gradually recognized high-speed rotary tablet presses from trial use, and there is currently a trend to replace them. Exploring the reasons behind this, I believe that anyone with a general understanding of high-speed rotary tablet presses would say that "the advantages are small sheet difference, high efficiency, energy saving, land saving, and high degree of informatization". Taking our company's high-speed rotary tablet press as an example, the tablet press manufacturer provides a summary analysis of cost-effectiveness from six aspects for users to refer to when selecting models.
(1) Significant energy conservation and consumption reduction. A high-speed rotary tablet press requires a purification workshop of about 20m2, while a low-speed rotary tablet press requires a total of 40-60m2. Due to the increase in purification area, the amount of purified air required for the production process also increases proportionally. If calculated based on an indoor height of 3.5m, a production time of 8h/d, and 15 air changes/h, the daily purified air volume required for the high-speed rotary tablet press and the low-speed rotary tablet press are 8400m3 and 16800-25200m3, respectively. Over time, the cost difference cannot be underestimated. In addition, during the tablet pressing process, in addition to the tablet press host, each host also needs to be equipped with auxiliary equipment such as a lifting feeder, vacuum cleaner, screening machine, and metal detection machine. Therefore, the overall energy consumption is the same as that of the purification system.
(2) High product yield. We know that the material loss in the tablet production process is mainly concentrated in two stages: the initial parameter setting and adjustment of the trial tablet, and the load reduction protection before shutdown. The normal production of high-speed rotary tablet press has a batch utilization rate of over 99%; However, low-speed rotary tablet presses are difficult to achieve this target, especially when multiple devices are selected, which will result in even lower costs and increase the chance of material waste by several times or even more.
(3) The direct cost of the equipment is basically the same. The price of a domestically produced high-speed rotary tablet press may be able to buy 4-5 low-speed rotary tablet presses, but low-speed rotary tablet presses must be equipped with multiple sets of auxiliary equipment, and the overall calculation will be almost the same.
(4) The cost of equipment management has been significantly reduced. The daily cleaning and maintenance of the tablet press need to be done according to regulations. In addition to labor costs, a large amount of consumables are also required, including drinking water, purified water, cleaning agents, disinfectants, and rust proof oil for protecting stamping dies. Obviously, the advantages of one set of equipment compared to multiple sets of equipment are self-evident.
(5) The labor cost has been greatly reduced. Domestic pharmaceutical companies generally assign 1-2 operators to each tablet press. For high-speed rotary tablet presses, due to the automatic control of tablet quality and other functions, one person can even operate multiple devices.
(6) High output yield. The output of a high-speed rotary tablet press is 4-5 times that of a low-speed rotary tablet press for tablet presses with the same diameter and similar punch modulus. The quantity relationship between a high-speed rotary tablet press and 4-5 low high speed rotary tablet presses is to achieve the same output in the same time.
Of course, there is still a slight drawback in choosing a high-speed rotary tablet press - facing production schedule risks. Once a sudden malfunction occurs and production is stopped, it will have a huge impact on output; The risk of low-speed machines with relatively low production is much smaller. Therefore, when selecting the type of tablet press manufacturer, it is necessary to start from the actual needs of the pharmaceutical factory, and also focus on the comprehensive balance of the high-speed machine's functionality, operational stability, safety and reliability, laboratory tablet press operation, cleaning and maintenance convenience, and timely service.