Tablet presses set new standards in tablet production

The new i Series features a dustproof construction as standard and can also be equipped with a containment package for processing active to highly active ingredients (Image: Fette Compacting).

The new machine generation is based on a common technology platform and is available in the models F10i, F20i, and F30i. (Image: Fette Compacting)

Any material blockages are prevented by a multi-format flow that minimizes friction. (Image: Fette Compacting)

The intuitive Human Machine Interface simplifies the monitoring and documentation of machine and process equipment. (Image: Fette Compacting)

The requirements for pharmaceutical manufacturing are constantly increasing, especially regarding sustainability, safety, and efficiency in various production environments. The new i series of tablet presses from Fette Compacting specifically addresses these challenges. It offers platform-based models that allow flexible adjustments and are characterized by advanced energy management and modern safety solutions. Furthermore, the machines are standardly dustproof and can optionally be equipped with a containment package. This provides optimal protection for operators up to safety level OEB4.

Thanks to their versatile applications, the new i series enables manufacturers to quickly adapt to market changes while complying with regulatory requirements. This combination of high flexibility and safety is the result of a completely redesigned machine generation based on a common technology platform. With three model variants, the series offers additional diversity for tailored alignment with the individual production requirements of pharmaceutical manufacturers: The F10i is optimized for flexible production of smaller batches, the F20i serves as a versatile all-rounder, while the F30i is designed as a double rotary tablet press for maximum production volumes.

Another advantage of all three models: they are system-compatible across generations. The process-relevant assemblies are identical to those of the previous i series, which is used worldwide by many manufacturers. Consequently, existing dies and segment rotors can be easily reused. This significantly shortens the qualification and validation time for a new machine—from several months to just a few days.

Dustproof construction and supplementary containment package from Fette Compacting

A central feature of the new generation of tablet presses is comprehensive operator protection. All models come standard with a dustproof design that extends from the press chamber to the interfaces between the machine and process equipment. A uniform negative pressure inside the press prevents dust from escaping to the outside. This effectively avoids contact between operators and pharmaceutical active ingredients.

To ensure maximum safety throughout the entire tablet production process, suitable technological solutions and a largely automated production flow are crucial. A tablet press must reliably and efficiently compress powders and granulates. Therefore, the machines of the i series can be equipped with a special containment package for the processing of medicines with active or highly active ingredients, achieving safety level OEB 4. In this case, special sensors monitor the safety of the entire system and warn of overpressure. If a leak occurs, the system emits acoustic and visual signals.

Fully automated tablet presses for increased safety

A fully automated tablet process further enhances operator safety. The containment remains actively sealed from filling the machine to removing the tablets. Access to the machine interior is via glove ports in the window panels, monitored by the machine’s safety control system. Each of these interventions is equipped with a safety sensor. A Rapid Transfer Port (RTP) allows for the loading and unloading of materials, tools, and punches. Additionally, access to the containment controls is restricted to authorized operators, and all inputs and changes are thoroughly documented in logs.

Tablet presses with a focus on sustainability

The new i series of tablet presses supports sustainability not only through high energy efficiency but also through environmentally friendly production processes. All models feature intelligent energy monitoring that records energy consumption in real-time. This allows users to precisely monitor and optimize electricity usage, reducing costs and improving the CO2 footprint. Thanks to improved cleanability and reduced maintenance effort, resource consumption decreases. This is partly achieved by reducing the cleaning surfaces by up to 74 percent, significantly shortening cleaning times and substantially reducing the use of cleaning agents and water.

Optimized tablet flow and rotor change system

Numerous design features contribute to the performance and versatility of the new i series. This includes the new multi-format discharge, which ensures a trouble-free process for different tablet shapes and sizes. The system minimizes friction resistance and prevents material jams, increasing operational safety and enhancing product quality.

An improved rotor change system significantly shortens the time required for component exchange and setup times. This allows switching between different products in just a few minutes. The F20i is equipped with a special mechanical manual rotor tensioning system designed for particularly quick and safe conversions. The rotor can be exchanged without special tools, making the machine ideal for production environments with frequent product changes.

Digitally connectable tablet presses for modern pharmaceutical production

In pharmaceutical manufacturing, where high efficiency and strict compliance with regulatory requirements are crucial, modern digital networking of tablet processes is becoming increasingly important. The new i series is well-equipped for this, as it is fully "digital ready" and can be easily integrated into digital production systems. Thanks to modern interfaces, the machines can be particularly easily connected with a Manufacturing Execution System (MES) and the Internet of Things (IoT). This enables continuous process monitoring and control, sustainably improving efficiency and compliance.

The user-friendly software simplifies operation and monitoring of the tablet presses. Various software solutions, such as the freely positionable Human Machine Interface (HMI), help less experienced users operate intuitively and avoid errors. With mobile monitoring functions, operators can access and manage production data in real-time on mobile devices, enabling quick responses to disruptions or deviations in the production process. Additionally, a Workflow Operation Wizard supports operators with clear instructions for standard processes. The wizard allows for convenient saving of work steps, setting process flows, and calling up checklists.

Additional output increase with FS12® punches

Tablet tooling is considered the performance driver of the entire tablet process, and efficiency can be further increased with the new i series through this route. Fundamentally, Fette Compacting’s tablet tools, through an optimal design of the tablet press, rotor, and tooling, significantly improve production efficiency. The optimal interplay results in longer tool life, reduced maintenance, and lower spare parts costs.

In addition, Fette Compacting offers, beyond the standard range of internationally normed punch designs, company-specific standards with the
FS®-Technology. All FS12® punches feature application-optimized head shapes and smooth running behavior, which optimizes the overall process—meaning increased compression hold time, quieter operation, and reduced wear on the involved components. Significant efficiency improvements are especially possible. For example, with the FS12® punch adapted to standard requirements, output can be increased by up to 40% without changing production time or additional personnel. The FS12® punch is compatible with all machines of the old and new i series, thus providing users with additional options for the optimal use of the three new models.

Future-proof with the new i series tablet presses

The numerous advantages of the new i series make pharmaceutical manufacturers future-proof. Together with a wide range of additional products, services, and consulting from Fette Compacting, the new i series is a comprehensive solution—even for complex tasks and the highest demands.