Fixing Tableting Problems

Tablet press adjustments can prevent manufacturing and product quality

problems.
May 02, 2015
By Doug Kirsch
Pharmaceutical Technology
Volume 39, Issue 5

Tablet compression is a science and an art, and a host of factors contribute to a

successful product run. Some of the most troublesome problems that
manufacturers encounter, including insufficient tablet hardness, inconsistent
tablet weight, incorrect flow of formulation through the feed system, and tool
damage, can often be corrected by making adjustments to the tablet press or its
systems. This article will discuss potential problems and how to adjust for them.
Specifying fill cams
Although many common tableting problems may be solved by making
adjustments to the press, it is just as important to select the proper machine
components, such as fill cams and feeder paddles. Choosing the correct fill cam
is crucial to clean press operation and consistent tablet weight. Rotary tablet
presses operate on the overfill principle, in which more powder is filled into the
die bores than required, and the lower punch is then raised to eject the excess
by the weight/dosing cam. This procedure is essential to obtaining consistent
tablet weight. If the fill cam is too shallow, weight variation may occur due to
insufficient die-bore overfill. If the fill cam is too deep, excess material will be
ejected onto the die table or reintroduced into the feeder, depending on the
type of press. If material is ejected back onto the die table, it will collect around
the neck of the turret and then be forced outwards due to centrifugal force. The
dies may then be refilled after passing over the weight/dosing cam, resulting in
weight variation. In presses where the excess material is reintroduced to the
feeder, it may undergo shear forces in the paddle feeder, resulting in particlesize reduction or densification, which affects tablet quality.
Correcting feeding and flow problems
A frequent problem with feeding material into the tablet press is bridging of
material in the hopper, which results in feeder starvation (i.e., no material in the
feeder) and/or overfill of the feeder, because the weight of the powder can
cause compaction. A lack of freely flowing powder can result in variation in
tablet weight. Material bridging can be identified by visual inspection through
the sight window in the hopper or feeder. If the press is not equipped with these,
problems can be observed by monitoring the progress of powder flow in the
hopper from above. Most commonly, bridging and other flow problems are due

to formulation issues such as cohesive formulation components, excessive

moisture, or irregular particle shapes.
Feeder paddle configuration also plays
an important role in tablet consistency,
because it affects die bore fill and tablet
weight, which correlate directly to proper
API dosage and are therefore crucial.
One simple, yet effective, feeder paddle
option is implementing paddles with a
45-degree angle on the leading edge of
the paddle blades (see Figure 1). This
configuration is particularly helpful with
light or fluffy formulations where
consistent die bore fill is problematic.
The angled blades direct powder down
rather than just pass it over the die
bores. This configuration has also
improved die fill with good flowing
formulations, resulting in standard tablet
weight deviation being reduced by as
much as 75%.
Most modern presses are equipped with
Figure 1. Angled blades on a feeder paddle
human-machine-interface-controlled
direct powder down (a) rather than pass it over operating systems. Tablet weight control
the die bores (b). All figures are courtesy of the is automatically adjusted by statistical
author.
process control based on compression
force. Theoretically, this would eliminate the need for the operator to make
manual adjustments, but these systems are not 100% reliable due to worn
parts, improper calibration, or software issues. An old school experienced
operater can sense weight variation by listening to, or touching, a press while it
is in operation and, based on the harmonics of the press sound and vibration,
can make manual adjustments to maintain proper tablet weight.
One way to correct flow issues is to adjust the formulation. If the formulation
cannot be changed, then the hopper will need to be modified, possibly by
fabricating a new hopper with an optimal wall angle to allow proper flow. Results
of powder rheology testing can predict the hopper angle needed for acceptable
flow or indicate the need to add a glidant to assist with powder flow.
Another method that can be used to encourage flow is to insert a vibratory rod
into the hopper transition to agitate the formulation. Mounting a vibrator directly
on the hopper may exacerbate the problem by causing product separation.

Adjusting press parameters

Several adjustments can be made to the tablet press to improve tablet hardness
and ensure proper die-bore fill and tablet weight. Proper rotation speed (i.e.,
RPM) of the feeder and turret as well as proper setting of upper punch
penetration and precompression are all crucial to achieving tablet hardness.
Rotation speed. Correct feeder RPM can affect tablet hardness by ensuring
proper filling of die bores. In addition, high RPM may induce particle attrition,
thus leading to compaction issues. The mating surfaces of the die table and
feed frame(s) must be properly aligned and adjusted for a press to run cleanly.
Lack of press cleanliness is one of the most common causes of press and tooling
failure. It is important to perform a visual inspection for wear or damage when
setting up the tablet press. These surfaces must be in good condition or
formulation leaks may occur, again affecting tablet weight.
Proper turret RPM can significantly affect tablet hardness. Sometimes it may be
necessary to slow the press down to increase dwell time to achieve proper tablet
hardness.
Upper punch penetration.It is generally
better to run minimal upper-punch
penetration (to help prevent air
entrapment) and to reduce tablet
ejection travel in the die bore. This
practice also reduces lower punch
movement, which generates heat. Heat
Figure 2. Increased upper punch penetration will is the enemy, because it increases
result in the punch head contacting the pressure sticking and picking issues. Increasing
upper punch penetration, however, may
roll further out on the head diameter, thus
aid in achieving tablet hardness.
extending compression time.
Because the punch heads will make
contact with the upper roller at an earlier point, compression time will be
increased. This parameter is not to be confused with dwell time, which is when
the punch head flats are passing between the rollers. Figure 2 shows how the
compression time is affected by the upper punch penetration.
Correct tool configuration can also affect dwell time. A "D" punch has a larger
head flat than a "B" punch, and the larger head flat generally results in a harder
tablet due to increased dwell time. When necessary, specialty or custom tooling
with larger head flats can be manufactured to increase dwell time.
Precompression. Precompression is probably one of the most improperly used
adjustments on a tablet press. Precompression is often set using a percentage of
final compression, but in the author's opinion, this method is not a good practice
because the operator does not truly know what is happening to the formulation

prior to final compression. If insufficient precompression is used, there may be

increased air entrapment, resulting in capping and/or laminating. If too much
precompression is used, a tablet can become fractured. Often mistaken for soft
tablets, fractured tablets are analogous to a safety glass window that has been
hit with a rock; it may remain in its original form, but it wont have any strength
due to all of the cracks that have formed. A tablet hardness tester will not be
able to distinguish between soft and fractured tablets. By setting precompression manually an operator can observe the effect of compression force
applied. With all main compression force backed off and turning the turret
manually, tablets should be formed at the ejection point but should be weak
enough to break apart when handled or ejected down the tablet chute. Minor
increased or decreased pressure adjustments may be required after start up, but
this is an effective beginning point.
Maintenance and training
Regular inspection and maintenance of the tablet press and its parts is
mandatory for successful tableting operations. In addition to proper cleaning
and lubrication, the press should be visually inspected as often as possible.Metal
parts should be checked for fretting wear (see Figure 3). Fretting on machine
parts is often misinterpreted as rust, but it is actually microwelding of two
mating parts that results from cyclic motion, due to increased clearances
created by wear. Fretting is most commonly observed on dies that have cracked,
which indicates worn die pockets. It appears at the top of the die as depicted
in Figure 3. The top of the die pocket suffers the most damage due to improper
die installation. Fretting can also be observed on punches, but does not appear
as clearly as it does on the dies or other press parts. Because punches are in
motion in their guides, residual
microwelded material is worn off.
The turret is the heart of the tablet
press; for successful tableting it is crucial
that the turret remains within
specification. Use inspection gauges to
confirm turret wear. These gauges check
the alignment between upper and lower
sections, punch guide/die-pocket wear,
Figure 3. Fretting wear appears at the top of the and punch-tip to die-bore concentricity. If
these areas become worn, tooling may
die.
be damaged resulting in poor table
quality. Worn turrets need to be refurbished or replaced.
Tablet presses are designed to allow for many automated and manual
adjustments. If press operators are not trained properly, however, these

adjustments can be useless. Operators must understand why the adjustments

are being made, and what impact they will have on the tablets. Nothing can
replace well-trained, experienced operators in ensuring product quality and
meeting production schedules.
About the Author
Doug Kirsch is technical service manager of the Tablet Press Division for Natoli
Engineering Company.
Article Details
Pharmaceutical Technology
Vol. 39, Issue 5
Pages: 58-59
Please cite this article as: D. Kirsch, "Fixing Tableting Problems,"Pharmaceutical
Technology 39 (5) 2015.