Tablet Press Control Systems

Press Control Systems

All Courtoy rotary presses can be equipped with automatic control systems, ranging from a simple PLC based system up to a complete fully automatic PC/PLC based system.

All systems are based on standard industrial hardware from the world leading manufacturers of automatic control systems. This means that no hardware is specially designed by Courtoy for rotary tablet presses. The use of such standard components allows for high reliability, while at the same time low cost replacement parts, available world-wide from local suppliers, within extremely short delivery times.

Weight control principle

Courtoy offers two alternative principles for automatic tablet weight control and adjustment, depending on the application and selected machine type.

The "force control" principle is based on measurement of final compression force under constant tablet thickness. This principle is used for all heavy duty applications where tablet weight accuracy and constant tablet density are less critical.

The "displacement control" principle is based on measurement of thickness variations under constant force. This principle is inherently more accurate then any force control system; and is therefor used in all pharmaceutical applications and in industrial applications where constant density of the produced tablets is critical.

Based on the measured signal - compression force or displacement - the weight control system will adjust automatically the fill depth to keep tablet weight within specified tolerance limits.

Four types of control systems are currently available from Courtoy:

• OC3
• ITS
• MC-3 Multi-Control (Available for Courtoy Modul™)
• Multi-Control 4 (available for the Courtoy Modul™ tablet press)

Tablet Press Control System - operator interface for OC3

OC3

OC3 is available on R100M, R0/2, R1/2, R53 and R5.

The OC3 is a basic production control system, based on an industrial PLC with a small operator interface panel. All machine adjustments are performed manually by hand wheels. Only the fill depth is motorised and adjusted automatically by the OC3 in order to keep tablet weight within the specified tolerance limits.

The OC3 allows for easy machine and production alarm identification, including identification of a defective punch.

The OC3 comes with a standard printer for on-line generation of a batch report.

Tablet Press Control System - Integrated Tableting Supervisor Control System

ITS

ITS is available on R090F, R190FT, R290F, R292F, R1/2, R53, R5, R233, R253, and R353.

The ITS - or Integrated Tableting Supervisor - is a state-of-the-art control system allowing fully automatic machine and production control, while at the same time is based only on a PLC hardware system.

The operator interface is based on a standard monochromatic graphical touch screen.

One single PLC is in charge of all control functions:

• Machine control: All machine adjustments are motorised for automatic machine set-up after product change over. Up to 90 different product recipes can be memorised in the ITS together with the corresponding tooling definition.
• Production control: automatic fill depth adjustment, rejection of out-of-tolerance tablets and identification of defective punches.
• Machine alarm monitoring.
• Peripheral equipment: tablet deduster, metal checker, printer and/or automatic powder feeding systems and tablet distribution systems.

The ITS allows even for the use of an automatic tablet sampling system: AWS (only weight measurement) or Combi-Test (weight, hardness, thickness). The tablet sample is automatically taken from the machine outlet, while the measured values are fed back to the ITS for automatic recalibration.

The ITS comes with a standard printer for on-line generation of a batch report, including measurement data from the AWS or Combi-Test.

MC-3 Multi-Control

MC-3 Multi-Control is available on R090F, R190FT, R290F, R292F, and R233.

The Multi-Control is the most complete system, based on a combination of an industrial PLC and a standard desktop PC.

The PLC performs all machine and production control functions (similar to the ITS), while the PC allows for additional features:

• Graphical colour interface with touch screen capabilities, eliminating any need for a key-board.
• User management system with individual password protection.
• Detailed batch reporting system, including trending analysis and distribution analysis.
• Easy integration in a local network, thanks to the standard PC used in the system.

Tablet Press Control System. Graphical interface examples of MC-3 Multi-Control

All Courtoy control systems are characterised by their extremely easy use and can be delivered with a complete software validation file.

Multi-Control 4

New generation control system offers:

• Password protection
• (according to the FDA guidelines)
• Audit trail
• Data proection
• Self explaining interface
• Statistical batch reporting
• Available with Allen Bradley or Siemens PLC

Which results in:

• Accurate control of the process
• User-friendly interface
• Detailed and configurable batch reporting
• Designed and validated according to GAMP 4.0
• Designed to be fully compliant with 21CFR PART11

Tablet Press Control System - Multi-Control 4. Graphical interface example 1

Tablet Press Control System - Multi-Control 4. Graphical interface example 2

Tablet Press Control System - Multi-Control 4. Graphical interface example 3

For further information about our process controls, process integration and process automation capabilities please read the Process Automation page.