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ACME_PROTAB

The document presents the Protab high-performance tablet press by ACG-Pam, designed to enhance Overall Equipment Efficiency (OEE) by maximizing machine availability and minimizing downtime. It features innovative technology for quick changeovers, easy cleaning, and smart operations, ensuring high productivity and compliance with safety standards. The Protab also includes advanced control systems and modular construction for ease of maintenance and operation.

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Sanjeev Ghosh
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0% found this document useful (0 votes)
22 views17 pages

ACME_PROTAB

The document presents the Protab high-performance tablet press by ACG-Pam, designed to enhance Overall Equipment Efficiency (OEE) by maximizing machine availability and minimizing downtime. It features innovative technology for quick changeovers, easy cleaning, and smart operations, ensuring high productivity and compliance with safety standards. The Protab also includes advanced control systems and modular construction for ease of maintenance and operation.

Uploaded by

Sanjeev Ghosh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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REDEFINE

OVERALL EQUIPMENT EFFICIENCY (OEE)


WITH
Designed for Highest OEE by enhancing the
AVAILABILITY of the machine

High performance tablet press with Professional


Features

®
The concept of an automatic machine has been taken to the next level. Every
process is simplified such that customer saves time in every step and process,
making the machine more available for production.
Come and experience a true marvel in Compression
Technology
: The High performance Tablet Press from ACG-Pam
The Protabis designed to make the operator’s life so easy that s/he falls in love with this
machine. Protab simplifies and minimizesthe time consuming steps involved in tablet
compression process. The numerous innovative features on Protab ensure maximum
uptime and availability, thus creating a revolution in the OEE standards.

Some of the compelling reasons why you should go for this technology:-

 The latest technology and engineering marvel from ACG-Pam to enhance the OEE
and minimize the TCO (total cost of ownership).

 The swiftest mechanical changeover (within 30 minutes).The faster the


mechanical changeover, the earlier the machine is available for cleaning and gets it
ready for production again. Benefit to you :- Faster changeover means higher
uptime and machine availability

 Easy cleaning: 360 Degree access, instant removals of the peripheral assemblies
(one minute each), light weight components, optimized plain contact surface areas
and a completely wire-free process zone! Even the engineering zone is designed to
have maximum access, visibility and cleanibility.Benefit to you: Quicker and
reproducible cleaning results, thus more up-time.

 Smart savings: Feeder left over less than 50gms, precise single sorting even at the
rated RPM (why to recall a batch due to a few out of weight tablets), uninterrupted
operations, time saving at every step starting from machine set-up, operations,
change over, cleaning and maintenance. Benefit to you: - Better yield for every
batch produced and maximum up-time.

 InstAmend Philosophy: Why to struggle when machine can do it for you!


Instant tooling setup, instant feeder height adjustment, instant faulty punch
detection, instant punch locating, Instant feeder dismantling and assembling,
Instant removal of Exit chute and dust extraction chute, instant removal of
peripheral assemblies. Benefit to you : Elimination and minimizing the down
time, maximum up time and availability

 Best of SHE compliances:Noise below 80 Db. (free field), Vibration-free,


minimalistic dusting, effective 260 degree dust extraction, Additional safety using
Multi Touch Operating panel. Benefit to you:- Compliance to CE, ISO and SHE
standards

 VISTARA Multi Touch MMI: Large Industrial Touch screen with Multi touch
features, similar to smart phones. The first of its kind in Pharma. Scroll with finger
between screens, zoom in and out, multiple app like screens for process, history,
reports, parameters along with live animation. Benefit to you : Smart operations
Acme Laboratories Ltd.
Dhaka, Bangladesh

Proposal “ACGBD/ACME/Protab/22052017

A Proposal from ACG-Pam

The Protab basic machine comes with the following components/ innovative
features:-

1.1 OPTIMIZED CONSTRUCTION & DRIVE

Optimized structure with combination of rigid cast iron frames and high tensile strength
pillars for maximum machine rigidity with absorption of vibration. The machine not only
performs but also is a marvel aesthetically.

Structure is provided with stainless steel cladding for protection.Four anti-vibration pads
are provided under the machine with max.load per element 800* daNProvision for crane
lifting and slots forfork truck lifting

Modular construction with four clearly separated and isolated compartments

 Drive module, containing Main servo drive and gear box, adjustment
motors,pneumatic systems,punch lubrication system and cooling unit with Electrical
connection box at the rear of the machine base.

 Pharmaceutical Compression modulecontains the Interchangeable Turret,


Compression rollers with guides and cam tracks. Lower Compression rollers and
Weight adjustment is totally separated from the remainder compression zone
‘through stainless steel guard.The middle enclosure and lower enclosures are
completely separate, thus sealing the engineering zone completely.

 Top module, containing drive motor for adjustment and feeder is separated and
easily accessible for maintenance.

 Electrical cabinet, containing the electrical and electronic components, including


the PLC and PC, placed inside an air cooled sealed Enclosure with IPC mounted on
the door, this way a separate standalone operating panel and cable is not required.
1.2 SIMPLIFIEDMACHINE HOUSING
Front chamfered machine housing with Lower guards in Stainless Steel and four large
transparent acrylic windows to give 360 degree accessibility all around the machine.
Lower Stainless steel guards are independent from the machine structure through
vibration dampeners and have no fixed connection.This construction reduces considerably
noise and vibrations,even at high compression forces and high speeds.
All windows are interlocked with magnetic polarity

1.3 DRIVE MODULE


Main servo motor and worm gear reduction box in bottom of the base module for maximal
vibration suppression
AC 3-phase servo motor with frequency control for a wide speed range can be stopped by
braking and restarted at any speed. Frequency control including overload protection


Special controlled backlash worm-wheel gearbox, to reduce noise and to provide constant
speed without ripple.
Vertical spindle rotating on oversized conical bearings, holding the Turret.
A coolingunit, based on air ventilation in the machine base improves cool air circulation.

 No wires in the engineering zone ensure easy cleaning ability.


 The drives, wires and electronic components are housed in a separate box for easy
access and preventing dusting in the electronic components.
 The engineering zone only contains, motor, cooling unit and the oil reserve for the
lubrication system.
1.43 PADDLE FORCE FEEDER
Light weight feeder for operator ease. The feeder can be assembled and disassembled
in less than 1 minute.

 Tool less assembly and disassembly ensuring maximum operator ease.


 Single drive shaft that can be easily removed and re-installed.
 The feeder left over is less than 50 grams ensuring maximum yield for your
blend.
 The feeder height adjustment is a patented design .the height adjustment is digitally
aided with height display on HMI reducing weight variation issues
 Linear height adjustment with least count of 1 micrometer.

1.5 POWDER INFEED


Powder is fed into the Tablet press through a stainless steel hopper of 11 litre capacity,
featuring with ISO 802 butterfly valve with 2 positions. The Hopper is isolated from
vibrations and is easily removable from inside the Pharmaceutical Compression zone
without removing any other parts.
 The 360 degree view for better visibility ensures that the operator can see the blend
flow from a distance also
 The powder flow is clearly visible even from a far distance.

Unlike competitor machines, no part is required to be removed in order to remove


the hopper;direct removal of the hopper ensures no time loss.

1.6 TURRET
3 piece cast iron Turret (1) Lower Turret (2) die table section and (3) Upper Turret
 Entirely nickel-plated, working surface of the Die table, hard chromium plated and
ground giving a flat and very hard surface for an ideal action of scrapers and
minimal powder loss.
 Spring loaded lower punch brakes for uniform filling with nylon tip to avoid damage
to the punches.
 Keeping the design aspect in mind, the turret can be completely removed with
the tooling for changeover ,
 Turret will be customized with 8 nos for D tooling & 8 nos for B tooling
 Tolerance levels ensures that no wear & tear in parts.

1.7 COMPRESSION CYCLE

OVERFILL

Overfilling is done under the First paddle of the three paddle feeder
Standard Delivered: One Fill cam of choice: 8, 10, 12, 14, 16, 18 (max.in case of B,BB and
BBS tooling) or 20 (max.in case of D tooling)
 Automatic identification of the installed fill cam and saved as product parameteris
part of the Basic machine

1.8FINAL FILL OR DOSING


Dosing or Weight Adjustment is adjusted in vertical position through the control system
using an motor with high precision control loop for accurate tablet weight control.Reduce
slope and with double sided flight control rails for uniform filling at high speeds.

 Lower punch tight detection through load cell


 Pedals have innovatively designed scrappers to ensure minimum leftover
powder.
 A re-circulation groove in the center of the Turret recovers the powder that escapes
between the feeder and the die table surface. This recovered powder is scooped
out of the groove and fed into the dies BEFORE they go under the feeder =
PRE-FILLING.
 Powder scraper is held through a spring force against the die table surface for
positive scrapping, it is outside the feeder which allows a very simple design, easy
for cleaning and installation.

1.9 PRE & MAIN – COMPRESSION WITH INTELLIGENCE


2 accurately dimensionally controlled hardened steel rollers, diameter 230mm, similar to
production presses to ensure ease of scalability.

 Self-lubricated sealed bearings and guiding


 Any time you start the batch, the initial lubrication is done by machine itself.
 Tablet thickness adjustment by motor and linear potentiometer in the Drive module
gives accurate punch position, which gives feedback to the closed loop position
control through control system.
 Overload Protection is through electro-mechanical protection system has greater
sensitivity to overload and reacts faster to an overload situation.
 The bigger roller provide very high dwell time for uniform compression ,housing
ensures minimum vibrations

The unique instAmend technology

1.10 EJECTION
Ejection cam with optimal curve,resulting in less chipping problems.
Exchangeable bronze wear plate with height adjustment.
Single sorting of out of specification tablets through integrated pneumatic rejection system
tablets.
Quick removal of Ejection Head, Single Lower tight punch can be easily removed.

1.11 TABLET CHUTE


A new design screws less and swing type exit chute helps enhance operator comfort to a
new level.
Innovation:-Imagine no wires or hoses in the exit chute and still the machine
perfectly single sorts tablet at rated rpm

 Light weight and easy to clean.


 Three channel chute for good, sampling and out of specification tablets.
 Group rejection flap and sampling flap.
 Completely sealed rejection coil for better cleanibility.
Additional flap and outlet for automatic sampling is available in the standard machine.
 Screw less and swing type exit chute.
 Separate assembly of coils for exit chute cleaning and washing
 Tool less assembly and disassembly
 A design that allows you to clean every corner without ever worrying about
quality check issues,we make it possible for you.

1.12 UPPER CAM

 Upper lifting and lowering cams are double sided(i.e. they act on both sides of the
punch) tominimize cam and tooling wear.
 Complete cams are mounted on bearings of the Turret. Atorque restraint bar
system prevents the cam from rotating with the turret.
 Upper Punch tightness detection, when the torque on the top cam surpasses a
pre-set value, the spring loaded system will move. Load cell detects & stops the
machine with corresponding alarm Upper Punch tightness detection is available in
the standard machine.

1.13 PUNCH LUBRICATION SYSTEM


Based on Volumetric dosage of oil quantity.
Oil and compressed air are mixed in adjustable proportion and conducted in a tube to the
point of lubrication, where they are ejected as an oil miston the punches.
Accurate control on the oil volume per stroke of the micro-pump
Totally separated lubrication systems for upper and lower punches, allowing independent
set-up Upper & Lower punches independently at 3 points: Punch body, inside punch head
and outside punch head.
All lubrication points are mounted rigidly inside the cam tracks and no position adjustment
is needed
1.14 LIGHTEST EVER DUST EXTRACTION SYSTEM
The dust extraction system is uniquely designed for maximum dust extraction. The
assembly is light weight and based on the plug and play philosophy for easy
removal and fixing in less than a minute

 Fixing and removal in less than a minute, tool less removal made possible
 Complete part made of high density polymers with light weight construction
 Separate provision for Upper and Lower punch suction to reduce black spots and
punch jamming.
 Provision for scrapper on die table for scrapping deposited fines.

1.15 CONTROL SYSTEM


The Protab has the next generation systems in computing. Data processing is fast and
comes with a plethora of features .The machine is 21 CFR Part 11 compliant adhering to
strict norms of Pharma industries.
A machine fully automatic in the true sense-Load the blend, put the parameters and
get HIGH QUALITY TABLETS.
SYSTEM

 Windows 8 ® operating system


 Intel I5 processor for faster processing needs
 19” multitouch screen for easy operation
 Finger print scanner for easy access

Some of the integrated features in the system designed are for maximum operator ease.

SETUP

 12 main parameters on main screen


 Animated GUI for easy understanding
 Digitally aided feeder height adjustment

OPERATION

 Insta-Amend technology for punch detection:- An innovative design that


removes handwheel operation completely, whether it is punch sticking or
tooling removal ,everything can be done directly.
 Rejection Analysis of Tablets
 Yield / Recipe /Batch reports
 Parameter categorization ( Setup/Operation/Lubrication/Compression)
 Virtual Turret Position detection
 Pre/Main Force Compression visual graphics
 Max individual Pre/main force digital display
 Histograms with sec/minute and hour wise viewing.
 Punch Position detection

MAINTENANCE

 Inbuilt Electrical drawings, Spare part Manual and Changeover Video


 Preventive maintenance and Calibration Schedule
 3D troubleshooting Help
 Electronics Overload protection.

OTHER
Tool kit for basic disassembling and cleaning operations
Calibration punches for calibration of the different height regulation units.
Electrical wiring and software control for peripheral equipment: tablet dedustor, metal
detector and/or automatic tablet sampling system. Connectors are nicely incorporated and
hidden behind the lower guards on the rear side.
Apart from all features mentioned above the machine is synonymous with reliability and
quality since we use the best parts to ensure reliability and quality to our customers.

Part Make Country of Origin


Load Cells HBM Germany
Gear Box Rossi Italy
19’ screen B&R Austria
PLC B&R Austria
Industrial PC B&R Austria
Sensors Wachendorf Germany
Main Motor Lenze Germany
Encoder Kubler Germany
Fill Cam Euchner Germany
Feeder Drive Schneider Germany
GUI Zenon Germany

REQUIRED SERVICES
Electrics: 415VAC/50Hz, 3 phases - 16 kVA* and ground connection
Compressed air: clean & dry - pressure between 250 l/min @ 6kg/sq.cm
Dust extraction: 11327 lpm at 10-12 mbar
2.0 TECHNICAL SPECIFICATIONS

PROTAB
The Protab is a single sided rotary tablet press, available for EU (or TSM) -Type standard
tooling and has the following technical characteristics for each type of tooling

Tooling D B BB BBS
(EU OR (EU OR (EU OR (EU OR
TSM) TSM) TSM) TSM)
Max.Tablet diameter(mm) 25 16(L=19) 13(L=14) 11
Punch Body diameter (mm) 25,35 19 19 19
Outside Die diameter (mm) 38.1 30.16 24 22
Die Height (mm) 23.81 22.22 22,22 22.22
Number of stations 21 27 34 36
Upper Punch Penetration (mm) 1 to 4 1 to 4 1 to 4 1 to 4
Max.Pre-Compression force (kN) 100 100 100 100
Max.Main-Compression force (kN) 100 100 100 100
Max.output capacity (tabs.hr)* 126,000 162,000 204,000 216,000

Electrical requirement 415V AC +/-5%,3 Ph +N +E, 16kW*

Compressed air requirement 250 lpm @ 6 kg/ sq.cm

Dust Extraction requirement 11327 lpm @ 10-12 mbar

Machine dimension &Weight W = 920 x L = 1000 x H = 2000 , 2500kgs

*Actual Speed will depend on the physical properties of the formulation to be compressed

**Countries where power supply standards are different ,the same will be provided as per
customer’s specifications
3.0 COMMERCIAL DETAILS

PROTAB BASIC MACHINE (QUOTED PRICES ARE IN USD)

S.NO DESCRIPTION Qty CURRENCY AMOUNT

PROTAB BASIC MACHINE WITHOUT TURRET, FILLCAM AND


TROLLEY CONTROL SYSTEM & STANDALONE OPERATING PANEL:

Basic machine includes:

A. Versatile Feeder with SS Paddles,3 pedal force feeder with


innovative design and <50gm left over powder

B. Human machine interface (IPC),19” inch animated display


A) for easy understanding 1 USD 1,80,444

C. Application Support Software for IPC, Xenon powered


system with a plethora of features

D. Auto weight Control system & accessories


E. Process control System & accessories
F. Electricals and electronics set up and wired for
functionality.
Total Rs.: 1,80,444

B) PROTAB TURRET
TURRET FOR PROTAB: - AVAILABLE WITH 8 D & 8 B FOR R&D
PURPOSE 1 USD 24,889

C) FILL CAM
FILL CAM:- FILL CAM ARE AVAILBLE IN SIZES OF 6, 8
,10,12,14,16,18,20,22 MM 1 USD 1,556

C) TROLLEY
1 TROLLEY FOR TURRET LIFTING & CARRYINGDURING CHANGEOVER
AND CLEANING,THE MOC OF TROLLEY IS SS316 FOR ALL CONTACT 1 USD 5,227
PARTS.

D) MACHINE OPTIONAL ACCESSORIES & FEATURES


FILL CAM CODER READER:- The code reader automatically detects fill
1 USD 2,769
cam type and uses the information for calculations
FILL CAM : CHOSEN TOOLING WITH TOOLING SIZES AVAILABLE FROM
1 USD 1,556
6,8,10,12,14,16,18,20 AND 22 MM
LOWER PUNCH TIGHT.MEAS.& CTRL ASLY(IH) USD 2.364
LOWER PUNCH TIGHT.MEAS.& CTRL ASLY(IH) USD 2,396
UPPER PUNCH PENETRATION USD 10,422
PRE COMP.FORCE MEAS.SYSTEM ASLY.(IH) USD 373
E) OPTIONAL ACCESSORIES & LINE MACHINES
CLIMATE CONTROL FOR CONTROL SYSTEM 1 USD 3,750
USD 3,329
ADU -DUST EXTN SYSTM WITH HEPA FLTR 1
USD 3,400
TRANSFORMER 20KVA DRY TYPE 3 PHASE GENER 1
USD 7,600
DIGITAL M.D. METALTRAP'03 AUTO BALANCE C 1
USD 22,773
COMBO UNIT ( METALTRAP HS30 + DD VERTICAL) 1
USD 8,000
PCS 200 AND ACCESSORIES WITH LEGACY 6100 1
USD 63,061
KRAEMER TABLET TESTING UTS4.1 BASIC M/C 1
USD 2,500
TOOL KIT FOR TABLT PRESS ASLY. (IH) 1

PACKING CHARGES USD 2,000


FREIGHT UP TO MANUFACTURING FACILITY At Actuals At Actuals
INSTALLATION, COMMISSIONING AND VALIDATION (7
USD 2500
WORKING DAYS)
VALIDATION DOCUMENTS USD 1500
COMMERCIAL TERMS AND CONDITIONS

Taxes &Duties: As applicable at the time of dispatch

Price: Ex Works, Mumbai

Freight: To Customer’s Account at Actuals.


Insurance: To Customer’s Account at Actuals.
Payment: 30% advance against order acceptance, 60% against Proforma Invoice and balance 10%
against installation & commissioning

Our Banker: STANDARD CHARTERED BANK, Crescendo,


C-38/39, G-Block, 3rd Floor,
Behind MCA Club, Bandra (East),
Mumbai – 400 051
A/C. NO. 22205294169

Installation & Commissioning: Time needed 7 Days after the machine is placed with all utilities provided.
Charges as per our Commercial Proposal.

Trial Material: Trial material required for taking trials of the change parts before despatch will have to be
provided by you FREE OF COST, freight fully paid to our Works on DDP basis. Exact quantity will be
informed to you at the time of order finalization.
Delivery Period: Within 16 weeks from our factory after receipt of your confirmed Purchase order along
with the advance payment.

Fat Charges: Travel and Accommodation to customer’s account.

Special Request/ Documentation: The prices indicated in the above commercial offer indicate our
standard offerings and Documents. Any special request for change in scope of supply or documentation
will be considered and commercial Implications will change our offer accordingly.

Validity: 120 days from the date of offer.

Place of Manufacturing: Kandivali, Mumbai, Maharashtra, India

Warranty: This warranty is valid for a period of one year from the date of supply for manufacturing
defects only.

Yours faithfully,
For ACG Pam Pharma Technologies Pvt Ltd

MD. FARID AKTER


MANAGER SALES – ACG BANGLADESH
Contacts

ACG-PAM Pharma Technologies Pvt.Ltd

Regional Sales

Mr Supriya Putatunda

Director – ACG Bangladesh

Phone No. +917738385934

E-mail:- [email protected]

ACG Bangladesh Pvt Ltd

Md. Farid Akter

Manager Sales

Phone No. +8801714122745

E-mail:- [email protected]

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