Compression tooling suppliers strive to meet the dimensional and performance requirements of their customers. We design, manufacture and deliver tooling to meet their needs and work to provide service after the sale to assist clients whenever the need arises. The reality about compression tooling is that the tools are a consumable item. Just like a pair of latex gloves; when the utility and value provided by the tools falls to an unacceptable level, the tools are discarded and replaced by new tools. The casual observer would surmise that since the tools are made of steel and are simply being used to press powders together that the tools would last a long time. If all powders were made the same and all tools were handled in the same manner then that might be the case. The reality is that many formulations are abrasive, some tablet presses are not well tuned and many compression tools are not handled in a friendly manner. The result is significant tool wear and shorter tool lifetimes.
Tooling care
It is typically not the fault of the tablet press mechanic or the tool room manager that they are not well oriented or trained on the proper methods to handle and maintain tablet compression tools. We often see punches and dies thrown together in pans and buckets with the attendant attitude that the tools are made of hard steel and how can this possibly impact the tools? The reality is that minor tool damage caused by mishandling can evolve to other problems. Taking short cuts during tablet press setup like skipping barrel lubrication, improper die insertion technique and failure to preload shaped punches before final die lock can impact tablet press wear along with tool wear due to improper lubrication. Tools left in a tablet press overnight in contact with formulation can lead to minor corrosion issues that are then amplified if the tools are cleaned in an ultrasonic bath and not properly dried and protected. As tools wear and are not inspected at uniform intervals then the tools can and will cause problems with tablet product quality. Failure to inspect and polish punch cups will lead to scratched cups that accumulate powder in surface blemishes in the cup, and sticking of formulation will result. Scratches on the barrels and heads of punches will impact the travel of the punch in the turret as well as the impact of the head with compression roller. Small problems can be propagated to big issues when one considers the high speed of modern tablet presses and the high compression forces often being utilized.
Ensuring long life
The handling, installation, cleaning, inspection, storage and refurbishment of tools play a significant role in determining tool longevity. Expectations for proper handling and maintenance of compression tools must be clearly communicated by plant management to all workers. Proper training must be provided so that every person, from the tool room manager to the tablet press operator understands that they own the responsibility for proper tool handling, care and press optimization. The protocols authored to address all of the aspects of tooling maintenance must provide logical steps that are coupled to the best devices available for tool maintenance. The care and maintenance path for a tool set taken from storage must be defined so that the tools return to storage in as close to the same condition as the tools which were removed from storage.
The cost of poor tool care and maintenance results in additional unnecessary tool purchases and that cost is passed along to the customer as a component of the higher costs of medicines as well as taken out of the pockets of company owners and shareholders. Implementing common sense policies to address tool handling and maintenance will provide a return on the investment in short order. Talk to your tooling supplier for advice and guidance and the result will be lower costs, better press and tool performance as well as fewer tools sets that have to be retired early.