Exploring The Secrets of The Three-color Tablet Press Machine
-An Efficient Tool for Production in Multiple Industries
Three-color tablet press is a device used to press three different colors or ingredients of granules, powders and other mixed materials into tablets or candies with three colors stacking effect at one time.
I. Wide Range of Applications
Three-color tablet presses are primarily used to press granular raw materials into tablets, and their applications are extremely diverse. In the pharmaceutical industry, they are key equipment for producing multi-layer tablets, precisely controlling the dosage and composition of each layer to ensure drug efficacy and stability. In the food industry, they are used to produce vitamin tablets, candy tablets, and other products, adding rich color and flavor. In the chemical industry, they are also indispensable for the production of detergent and disinfectant tablets. The electronics and ceramics industries also rely on tablet presses to produce electronic component tablets or ceramic tablets with specific functions. Furthermore, depending on the order, they can also press round tablets, special-shaped tablets, and double-sided engraved tablets, fully meeting diverse production needs.
II. Working Principle
Three-color tablet presses typically utilize a three-press automatic rotary mechanism for continuous tableting. The core process is as follows:
- Filling Stage: The lower punch first extends into the bottom of the die hole, sealing the hole and creating a space for the raw material to be filled. At this stage, granular raw materials of different colors or compositions (using a three-layer tablet as an example) are fed sequentially into the middle die hole through separate feeders in a pre-set order.
- Pre-pressing Stage: The upper punch slowly descends to initially compact the filled raw materials. The pressure during this stage is generally 1/10 of the final final pressure. Pre-pressing expels air between the raw material particles, stabilizes the particle stacking structure, prepares for the subsequent final pressing, and prevents delamination and misalignment during the final pressing process.
- Main Pressing Stage: The upper punch continues to apply high pressure, typically ranging from 20-50 kN, using a multi-roller system to compact each layer of raw material. The strong pressure tightly binds the particles together, forming a solid tablet. However, it should be noted that unstable pressure can easily lead to quality defects such as loose tablets or capping.
- Tablet Ejection Stage: The lower punch rises to eject the compressed tablet from the die. The tablet is then smoothly ejected through a baffle. Since there are different color layers in the three-color film, in order to prevent inter-layer contamination, the equipment is usually equipped with a dust suction device to promptly remove the dust generated during the pressing process and reduce the pollution risk caused by dust diffusion.
III. Structural Features
- Multi-Press and Feeding System: Commonly used are dual- or triple-press structures, equipped with two or three independent feeding devices and press wheels. This design allows for separate pressing of different colored tablet layers, meeting the production requirements of multi-layer tablets.
- Turntable and Active Punch: The machine's internal turntable can be equipped with a large number of active punches, allowing multiple tablets to be pressed simultaneously during each rotation, significantly improving production efficiency and making it ideal for large-scale production.
- Variable Frequency Drive: Utilizing variable frequency drive technology, it offers electrical speed control. This speed regulation ensures smooth operation and allows operators to quickly and easily adjust the speed according to production needs, making operation simple and flexible.
- Dust Collection and Protection: To prevent cross-contamination caused by mixing of different colored materials during the pressing process, three-color tablet presses are typically equipped with an external dust collection device or powder extraction box. Furthermore, the machine's exterior housing is generally fully enclosed, made of stainless steel, with the internal countertop also constructed from stainless steel, maintaining a glossy surface and effectively preventing contamination. Some machines also feature transparent protective covers, allowing operators to clearly observe machine operation. These covers can be fully opened for easy cleaning and maintenance.
IV. Performance Advantages
- Powerful Pressure and Smooth Speed: The tablet press can provide high pressure, meeting the demands of compressing large and difficult-to-form tablets. Furthermore, its smooth speed and reliable performance ensure consistent and stable product quality, even during long-term continuous production runs and with varying raw materials.
- Easy and Efficient Operation: All controls and operating components are strategically arranged, making operation easy for operators. Some machines are equipped with a human-machine interface variable frequency speed controller, enabling convenient electrical speed control and a reverse rotation function, further enhancing ease of operation. Furthermore, the machine can be tested and adjusted without stopping, significantly reducing production setup time and improving production efficiency. Impressive Production Capacity: Common models, for example, can reach thousands or even higher tablets per hour. For example, some models can reach a maximum output of 21,000 or 23,000 tablets per hour for three layers, meeting the needs of large-scale production.
- Precise Dosage Control: Advanced weight-adjusting cams and precision dies collaborate to precisely control the fill level of each layer and tablet thickness, ensuring the correct dosage for each tablet and meeting stringent industry quality standards.
V. Key Operation and Maintenance Points
Operating a tablet press requires professional training and familiarity with the equipment's operating procedures and parameter settings. Before starting the machine, carefully inspect all equipment components for proper function and ensure that the raw materials are prepared as required. During production, closely monitor equipment operating conditions, such as pressure, speed, and tablet weight variation, and promptly adjust any abnormalities. Regular maintenance is also essential, including cleaning the surface and interior, inspecting the dies for wear, and lubricating the drive system. The transmission system is usually enclosed in an oil tank below the machine body. As a safety-separated component, ensure that it is adequately lubricated to reduce noise and wear. Regularly check the performance of the dust collection device to ensure it is functioning properly and effectively prevent cross contamination.