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Maker - Product Challenge

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Vitamin C compaction Equipment

Compaction machines and technologies crush or compress materials and make them denser. Compaction can be used to simply save space or to shape materials into a desired form or format. Tablets, pellets, or briquets are formed by compactors but powder presses also help form cosmetic eyeshadow or face powder.

Compaction

Vitamin C is an essential nutrient, but the human species lost the ability to produce it biologically during the course of evolution. Instead, we source the substance either from whole foods or vitamin C manufacturing. The chemical characteristics of the natural nutrient and processed compound are the same, but supplements offer higher concentrations, especially to persons with nutrient deficiencies.

Vitamin C

Production of certain pelletized products requires working with output products of a pasty consistency. These products include pigments, clay, detergent additives, vitamin products, and many other products where problems of adhesion of fresh pellets are often encountered. Processing of these types of products requires a pelletizing press that allows the fresh pellets to be directly deposited on a gently transporter such as a conveyor.


<h2>A pelletizing press for depositing pellets directly onto your conveyor</h2>
Amandus Kahl produces pelletizing presses with overhead drives that allow pellets to be deposited directly onto a conveyor from above-eliminating the adhesion issues of fresh pellets often encountered with pasty products. This line of presses uses the proven technology of Amandus Kahl’s other pelletizing presses but the drive unit is above the pelletizing die rather than below it allowing gentle direct deposition of the fresh pellets onto a conveyor. The presses use pan grinder rollers to compact the input material and force it through a pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives.

The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimizing generation of noise and heat. The grinder roller speed is infinitely adjustable. The grinder roller gap and strand cutter are also adjustable for optimized pellet quality for the customer’s particular needs.

Pellet dies are readily changeable without specialized tools for easy experimentation and process development aiding the customer in developing a process that is optimized for their product. A Kahl variable speed proportion screw is often used in conjunction with these units to ensure consistent and uniform feeding of raw materials.

Pelleting press with overhead drive

Creating batches of consistent high quality pharmaceutical grade tablets from your powdered ingredients requires equipment that complies with strict regulations and record keeping requirements while at the same time is flexible and easily adapted to a variety of products.  Easily maintained, equipment with quick tooling changeovers and faulty punch detection gives producers the worry-free tablet production capabilities that they need to be competitive.


<h2>A simple and robust tableting platform for efficiency and regulatory compliance.</h2>
The Protab 300 from ACGE is a simplified rotary tablet press with features designed specifically to meet the demands of today's small and medium batch pharmaceutical producers.  It is designed for easy maintenance, rapid changeover, high reliability and Overall Equipment Efficiency in general.  A dust extraction system , feeder assembly, turret, and exit chute assemblies have all be rethought and include features such as auto-lubrication, swing-in swing-out design, modular design of supporting assemblies to ease machine use and increase production efficiency.

ACGE's Protab 300 also includes features that assure a tablet product of the highest quality including digitally aided feeder height adjustment, precise tablet weight control, and safety features such as process interlocks and noise reduction.  Productivity is enhanced with higher machine up-times, low feeder leftover losses, improved paddle design for elimination of dead zones, and and intelligent 'batch over' detection system.

Single rotary tablet press

Successful pharmaceutical manufacturers know that high quality, reliable equipment is essential in order to be competitive in highly regulated and highly dynamic market.  Reliable, flexible forming equipment that works with a variety of tooling types and is adjustable to meet the needs of different products gives producers peace of mind.  A tablet press with full audit trail compliance from a world renowned pharmaceutical equipment supplier is certain give any high volume pharmaceutical producer an edge over the competition.


<h2>A tablet press with premium features and low cost</h2>
The Legacy 6100 tablet press from ACGE is a tablet press of proven design and well known quality.  The consistent, high quality production and user friendliness demanded by today's producers as well as a low upfront cost and revenue optimization features make this unit the ideal choice for high volume tablet production in a competitive environment.

The unit includes 10 tonne compression rollers in both the 1st and 2nd stages and well-tuned dwell time to ensure gradual compression.  Non-complying tablets are identified and sorted automatically and product recipes and production parameters are stored internally.  The system is designed for economic operation and includes features for easy cleaning, and rapid change-over, as well as a online support and video training materials to ensure competent and confident operators and efficient production.

Economic tablet press

<span style="font-weight: 400;">Automated pressing of tablets saves time and improves quality. In R&amp;D or laboratory environments a dedicated minimal form factor tablet press provides maximum flexibility for the production of smaller batch sizes.</span>
<h2>Plug-and-play tablet press designed for lab and R&amp;D environments</h2>
<span style="font-weight: 400;">The Sejong Pharmatech P130S has been designed from the ground up as a lab-scale tablet press, and offers features that make it extremely flexible in pharmaceutical R&amp;D.</span>

<span style="font-weight: 400;">Available in 3 models offering 9,600, 19,200 and 24,300 units per hour, the P130S is capable of producing both round or oblong tablets up to 25mm across and up to 8.5mm in depth, allowing for a wide variety of sizes.</span>

<span style="font-weight: 400;">The unit has a mechanical bar and round type feeder and offers full automatic weight control (AWC) for the rejection of any faulty tablets, removing the need for manual intervention for quality control.</span>

<span style="font-weight: 400;">Featuring a full touch screen interface, the P130S makes it easy for operators to control all aspects of the machine’s function via a graphical HMI. The control system features full 21CFR part 11 reporting compatibility, offering simple regulatory compliance.</span>

Lab scale single layer tablet press

<span style="font-weight: 400;">High performance tablet presses for the modern production environment need to be fast, accurate and flexible. Rapid changeover, simple operation and high volumes with minimum rejection rate are all key features required, as well as minimal maintenance and user intervention.</span>
<h2>Medium volume tablet press with reduced maintenance</h2>
<span style="font-weight: 400;">The Sejong Pharmatech P420S series of tablet presses have been designed to offer immediate productivity improvements to tablet production lines. Designed to provide up to 10,000kgf of pressure and outputs of over 300,000 units per hour, these units offer some of the highest levels of performance with low cost of operation, and can produce round or oblong tablets up to 25mm diameter/length and up to 8.5mm thickness.</span>

<span style="font-weight: 400;">The P420S series features an efficient single impeller feed system, reducing the number of parts required and simplifying and speeding up cleaning and maintenance. A new design of powder feed pipe improves powder flow, allowing for greater efficiency and higher output compared to other press designs.</span>

<span style="font-weight: 400;">The user interface is based on a clear 15” touch screen display, with clear and simple layout and controls. Advanced features include a completely graphical error display system in case of malfunction or performance issue, directing operator to the fault for rapid resolution. The operating system is fully 21CFR part 11 compatible, meaning record keeping for regulatory compliance and optimum performance is simple.</span>

<span style="font-weight: 400;">The P420S features a fully automatic discharge chute with sample gate. Rejected tablets are also automatically sorted when the machine sensors detect a defective tablet or as a result of the automatic weight control system.</span>

<span style="font-weight: 400;">All punches and rails are protected by advanced load cells that constantly monitor the machine performance and prevent these vital parts from damage, prolonging machine life and reducing maintenance. Upper and lower punches benefit from an automated lubrication system, removing the need for operator input.</span>

Single layer tablet press

The traditional method for gummy and jelly production uses starch to keep the ingredients from sticking to the mold trays. But, as an organic byproduct, starch raises concerns about microbial contamination. Moreover, starch leads to coarser edges of individual sweets, lowering the quality of the end products. The use of starch presents many hygiene and cross-contamination risks, as well as efficiency, quality and financial compromises.

<h2>Make high-definition gummies that are free from starch</h2>
The ServoForm Flexi system for gummies and jellies from Baker Perkins is designed for starch-free production. Starch-free depositing is both more hygienic and economic than traditional starch mogul production for the lower throughputs that are typically required for functional, nutraceutical and healthcare markets.

The ServoForm Flexi system offers the capability to produce gummies and jellies with longer setting times. 3D, solid, striped, centre-filled and layered products with gelatin, pectin or specialized gelling agents are deposited at final solids so no drying is required, only setting/conditioning.

A unique single-piece plastic mould allows for rapid product changeovers. The strong, rigid construction provides resistance to twisting to maintain depositing accuracy and stack stability, and is designed to survive both manual and automatic handling for multiple cycles. They are temperature resistant to allow hot product and automatic washing.

Flexible Output Line For Gummies and Jellies

Tech is [was] keeping vitamin gummy manufacturers from cutting starch

Chewy, sweet, and nutritious. Vitamin gummies were a couple’s attempt to get their child to take their essential micronutrients. The idea quickly caught on, and manufacturing vitamin gummies soon grew into a whole new industry.

Vitamin gummies

Gummy candy are a very popular confectionery, because they are versatile and appeal to a wide variety of tastes. Another reason for the popularity of this delicious candy is the fact that it’s easy to produce, particularly in small quantities. For medium to large scale production of gummies, there is a multitude of gummy manufacturing equipment to help ensure that you end up with a good product.

Gummies

Baker Perkins supplies technology for the bakery, biscuit, confectionery, supplements, snack and breakfast cereal sectors, The company's production machines are based on over 100 years of experience in the field.

When the starch mogul was first introduced in the early 1900s, it revolutionized the way jellies and gummies were produced.

The machine punched a mold into a bed of starch, much like an industrial cookie cutter. The gelatinous mixture was left to set until the starch absorbed enough moisture to produce a solid.

Although gums took hours to form, the technique relatively quick method for mass-producing candies in a more-or-less consistent shape. But it didn’t come without its costs. Manufacturers now needed extra space for starch rooms and a whole new process of filling starch trays, then separating the starch from the formed candies and drying it again for re-use.

Nevertheless, the clouds of starch particles that filled the shopfloors were a step forward from the laborious hand-forming of the day.


<h3>New gummy products, old manufacturing methods</h3>
The mogul technique is still widely used today, but gummies have changed considerably over the decades. Gummy products have expanded to include medicated formulations like vitamin gummies. Meanwhile, greater awareness of the contamination risks associated with starch is prompting regulators to introduce stricter validation standards for manufacturers.

Bulk starch sitting in storage is fertile ground for microorganisms, including pathogenic ones. This raises a new set of challenges, particularly for producers of vitamin gummies. They must constantly monitor the starch for microbial contamination and treat it with radiation before using it.
<h3>The time of starch-free production technology</h3>
Baker Perkins developed a system to manufacture high-quality gummies without any starch. The syrup formula is accurately deposited into 3D molds made from food-grade material.

But besides eliminating contamination issues, removing starch from the process simplifies the operation. No tray-filling, no handling issues, and no starch drying. In addition, the system allows manufacturers to form high-definition vitamin gummies with multiple coloring possibilities.

Unlike traditional methods, starch-free production simplifies demolding while fully preserving the shape of the gums. Keith Graham, marketing manager at Baker Perkins, explained to us how the combination of the mold material, the surface finish, and a special spray solution impacts the end product. “Getting these parameters right is the key to achieving 100% demolding.”

The reasons to move past the starch mogul have been mounting for years. But, just like the time the mogul was invented, the industry needs an efficient alternative to take the leap.

Baker Perkins has roots in the same era when the starch mogul became the obvious way to produce jelly products. The next step forward is taking vitamin gummies starch-free.

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Food

Pharmaceutical

To make candy, all you need to do is create a syrup by dissolving sugar and boiling it to your desired consistency. For medium to large scale candy production, candy making equipment fully automates the whole process and takes care of other production regulations and standards (such as hygiene and proper homogenization). Planning on getting one? There’s a wide range of choices to pick from.

Candy

Eating is more than just nutrition, but we have found ways to increase the nourishing power of our foods. Nutraceuticals manufacturing, from vitamin C powder and probiotics to omega 3 oil, is a concentration of natural ingredients and health supplements that complement our diets. While dietary supplements are not quite haute cuisine, the process of extraction and purification is no less a blend of science and art.

Nutraceuticals

Find production technology for Vitamin C compaction, and connect directly with leading machine manufacturers worldwide

Vitamin C compaction Equipment

Which vitamin c compaction equipment do you need?

Pelleting press with overhead drive

Single rotary tablet press

Economic tablet press

Lab scale single layer tablet press

Single layer tablet press

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