A high output (suitable for large batch production more than half a million tablets / hr. Max.) double sided tablet press with pre-compression and hydraulic power pack and auto lubrication. Designed and engineered to adhere the latest cGMP standards. Suitable for PLC operations as optional Ability to incorporate so many customized functions and features.

1. Faster

Higher Output:-

More than half a million tablets / hr. max. Perfectly suitable for large batch production.

Quick & Easy Tool Changeover:-

All upper punch guards are fitted with least screws, which allow for rapid removal and immediate access for the punch zone. Upper punch removal is further made quicker by means of the large upper punch retaining plate which when removed , allows up to about 10 punches to be replaced in one setting. The easily removable weight adjusting section increases speed of lower punch and die removal. When removed, three lower punches can be replaced in one setting.

Hand wheel is conveniently located near punch loading point for indexing the turret during tool changeover.

2. Fascinating

Designed with the latest in the tablet press technology, Giga Press incorporates many of the proven features of our own designed and widely accepted in the market - Mega Press.

Main Pressure & Pre-compression System :-

Giga Press is fitted with Pre-compression system on each side. The large diameter main & pre-compression rolls have been designed to ensure the optimum dwell time for the punches under pressure. The pre-compression system gives better compression, better weight control and luster of tablet with Low Bulk Density Granules (fluffy powder). Pre-compression roll setting is provided inside the compression zone.

Punch Penetration: (3 mm to 8 mm). This feature is mainly useful for compression of the SHALLOW TABLETS. In addition to it, Punch Penetration gives following benefits by

Hydraulic Power Pack System For Pressure Loading and Overload Release:-

The pressure units are self-contained and do not transfer stresses to any other parts of the machine. Pressure is applied by means of Hydraulic Power Pack System which maintains constant hydraulic pressure. The overload release on both upper and lower punches provides an extra safety guard against overload.

Both the upper and lower rolls are adjustable, allowing variation of position at which the tablet is made in the die.

This system ensures that any overloading transmitted to the punches is only a small fraction of the total loading. This is particularly essential with difficult materials or when thinner tablets are being produced.

Lubrication System :-

The lubrication system of Giga press is combination of ...

1) Continuous Lubrication
2) Intermittent Lubrication

The gear drive and turret bearings are continuously pump lubricated., In the intermittent lubrication system, at regular preset time interval a fixed quantity of lubricant is splashed at various points. All pressure pins are lubricated by an automatic intermittent forced feed system and lubrication is provided to the punch heads.

Low Noise & Vibration:-

The compression zone of the machine is totally enclosed to minimize noise level. The outer lining of stainless steel, soundproof transparent upper guards with large thickness reduce the sound level drastically. Powder zone completely separated from mechanical zone. Highly polished Close tolerance cam profile ensures the smooth running with low wear & vibration and low noise generation. Anti vibration mountings are provided to minimize machine vibration. By virtue of hydraulic pressure the punch head noise while compression is reduced drastically.

AC Inverter Drives (ACVF) for main motor and force feeder motor: -

Highly Efficient AC drives give better control, ease in operation and flexibility over the speed hence better control over production of tablets.

Ejection Chute:-

In order to reject all start up and run down tablets, this chute is fitted there and it is controlled by the pre set timer.

3. Facile

The Giga Press has an integral frame, in the center of which is housed the main drive assembly.

Drive Arrangement :-

The drive is transmitted from the 3-phase electric motor with variable frequency control to gearbox through timing belt. Electrical and mechanical safety devices are installed. The final drive is by replaceable helical gearing. The turret is mounted on Bronze bushes and antifriction thrust bearings. The oil immersed reduction gearbox is centrally located in the lower part of the tablet press which is fully ventilated to avoid overheating of mechanical parts during continuous service condition.

Feeding of the Material:-

Giga Press is fitted with easily removable bottom driven rotary force feeders specially designed for high-speed operation of the machine. Higher tablet weight consistency and operational cleanliness are ensured. The feeders are driven through variable frequency drive for optimum performance over wide range of materials and Tabletting speeds. The feeders are fitted with discharge chute which, when used with the hopper cut off slides, allow the feeders to be emptied before removal.

This facility eliminates powder loss and reduces cleaning time.Material flow from hopper to the feeder can be easily regulated within finer limits without having machine shutdown. Powder spilling losses are kept to an absolute minimum by the powder-circulating band fitted to the feeder. Adhering to cGMP norms, no other driving components of the machine is located in compression zone.

Parameters Control at front from Outside the Machine :-

Front controls are provided on machine front by means of Seiko Dials for tablet thickness, Lower pre-compression roll, and upper punch penetration for front as well as rear side machine operation. Also Auto lubrication control, force feeder speed regulator and Hydraulic system controls are provided on front panel . Outside control facilitates setting or fine-tuning of machine parameters during machine operation with assurance of operator's safety.

Quick Cleanliness :-

Spacious cabinet combined with counterbalanced acrylic cover guards (dustproof) gives excellent access to the area for cleaning purpose. There are no dust traps in the compression zone. Lower punch scrapper seals prevent material passing through the lower punch guides into the cam tracks. This results in reduced wear and extended tool life. Dust extraction points significantly reduce dusting at the time of compression, enabling the machine to run for longer periods without interruption for cleaning.

Giga Press is provided with detachable control panel for cleaning & steam wash required for product change. When process demands for steam wash for product changeovers, with help of detachable control panel; all electrical components are separated from the machine. This prevents short circuit or sparking due to condensation of moisture on electrical components.

4. Fabulous

Machine Height and Control Station Design :- The height of the machine and the control panel is so designed that the operator can work on the machine without having fatigue and with ease. Ease of Visual Inspections:- The stainless steel hoppers have acrylic window for visual checking of powder level.

Operator Safety:-

Safe machine operation is of utmost importance. To ensure safety, all upper guards have been fitted with interlock switches. In addition, a warning light on the machine top gives visual indication that a guard is not properly closed. An emergency stop red button is fitted at approachable distance to stop the machine. A simple to operate control panel at the front of the machine allows convenience and safe adjustment of operating parameters.

Proper Identification :-

Universally accepted symbols are used for proper identification of the parts and process sequence in order to make the operation and maintenance user friendly.

5. Flexible

Fill Cams:-

Three sets of fill cams cover the full range of depth of fill using right size of fill cam will ensure help smooth operation of the machine and prevent overloading of rotary feeders, reduce carryforward powder & clean operation.

Other optional features can also be provided as per the requirement:-

• S.S. 316 Contact parts
  
• Upper Punch Cup Seal.
  
• P.L.C. System.
  
• Polycarbonate Upper Cabinet Guards.

6. Faithful

Fully conforming to the requirements of cGMP:-

Giga press has been built in accordance with cGMP requirements and being prepared to meet the requirement of schedule M.

Standard Documentation: DQ/IQ/OQ/PQ:-

Design Qualification/Installation Qualification/Operational Qualification/Performance Qualification documents can be provided along with the machine.

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