In
tabletting, it’s unavoidable to have one or a few problems but those problems
can be cured with certain ways. Below are problems in tablet finished
product along with their possible causes and cures:
PROBLEM
|
POSSIBLE
CAUSE
|
CURE
|
Inconsistent
Weight
|
Variation in punch length (lower)
|
Replace or regrind to length
|
Inconsistent granule
|
Improve granule / mixing technique
|
|
Empty feed frame
|
Check hopper / feeder, ensure granule
flows freely
|
|
Punch holding plugs
|
Replace
|
|
Dirt under weight adjustment ramp
|
Remove ramp, clean
|
|
Incorrect setting of feeder paddle
speed
|
Adjust as required
|
|
Incorrect setting of feeder inlet
bowl
|
Adjust as required
|
|
Tablet
stick to upper punch
|
Damaged upper punch
|
Refurbish or replace punches
|
High moisture level in granule
|
Dry granules in oven or F.B.D., sieve
and lubricate
|
|
Lack of, or insufficient lubricant
|
Add or increase lubricate
|
|
Double
impression
|
Worm punch holding pads
|
Replace
|
Excessive tamping force
|
Increase tablet thickness
|
|
Flash'
on tablet edge
|
Worm punch or die
|
If possible reverse die or replaace
badly won punches
|
If tapered dies are being used tablet
compressed in taperd section of die
|
Increase upper punch penetration
|
|
Variation
in thickness / hardness
|
Worn pressure roll
|
Replace
|
Variation in upper or lower punch
lengths
|
Replace or regrind to length
|
|
Inconsistent granule
|
Improve granule
|
|
Overload pressure, setting set too
close to tabletting pressure
|
Reset
|
|
Safety
overload pressure release operating
|
Damaged punches (burr on tip)
|
Refurbish or replace
|
Excessive pressure
|
Reduce pressure, i.e. increase tablet
thickness or reduce fill
|
|
Overload set to close to tabletting
pressure
|
Reset overload
|
|
Lower
punch
|
Mtl stuck to punch or die
|
Check for worn punches and dies
|
High moisture level in granules
|
Dry granules in oven or F.B.D., sieve
and lubricate
|
|
Top
of tablet is split / cracked
|
Damaged punches
|
Refurbish or replace
|
Granules maybe too dry
|
Add moisture, remix, granulate,
lubricate
|
|
Tablets
breaking on take off
|
Take off plate incorrectly set
|
Check and reset
|
Lower punch ejection
|
Check and reset
|
|
Insufficient load at compression
point
|
Increase pressure, check overload
|
|
Speed too high for particular
material
|
Reduce speed until acceptable tablet is obtained
|
|
Not enough binder
|
Increase
|
|
Granules too dry
|
Increase moisture level
|
|
Insufficient feed to dies (soft
tablets)
|
Check hopper and flow of material
|
|
Feeder height incorrectly set
|
Check and reset
|
|
Tablets
binding in die
|
Worn dies
|
Reverse or replace
|
High moisture level in granule
|
Dry, sieve and lubricate or reduce
fill
|
|
Lack of, or insufficient lubricant
|
Increase
|
|
Tablets
split in half (lamination)
|
Take off plate incorrectly set
|
Check and reset
|
Lower punch ejection incorrectly set
|
Check and reset
|
|
Speed too high
|
Reduce speed
|
|
Insufficient feed to die
|
Check hopper and flow of material
|
|
Worn / damaged punches
|
Refurbish or replace
|
|
High moisture level in granules
|
Dry in oven or F.B.D., sieve and
relubricate
|
|
Not enough binder in mix
|
Increase
|
|
Excessive pressure
|
Increase tablet thickness
|
|
Granules too dry
|
Increase moisture level
|
|
Burr or punch tips
|
Refurbish or replace
|
|
Feeder height incorrectly set
|
Check and reset
|
|
Loss
of material
|
Feed frame / pedestal height
incorrectly set
|
Check and reset
|
Upper punch penetration set too high
|
Check and reset
|
|
Worn lower punches or dies
|
Replace
|
|
Tail over die / scraper set / worn
|
Check, reset or replace
|
|
Recirculating channel worn or missing
|
Replace
|
|
Indequate dust control unit
|
Overhaul or replace
|
|
Excessive flow of material to feed
frame
|
Reduce flow
|
The
cures that have been explained are merely a guide because there are many cures
that can also solve the same problem/s. One of the most critical parameters
that has to be assured is how to make a proper mass that will suit the
specification of the finished product the best.