Interpack 2014: Fette Compacting FE75 Offered Top Performance for Large Batch Production

The new FE75 rounds off Fette Compacting’s innovative FE Series. Users can equip this high-performance double-sided rotary press with up to 115 punch stations and produce more than 1.6 million tablets per hour. The FE75’s four compression rollers enable it to work with two intermediate pressures thanks to a special control system for direct compression. The result is a 166 percent increase in dwell time with FS19 punches. With a footprint of only two square meters, the FE75 also sets new standards in terms of its size and space requirement.  

The production of large batches makes special demands on tableting technology. The output of a rotary press usually depends on the number of punch stations and the speed of the turret. It has therefore generally been the case in the past that the higher the required output, the larger the machine. However, any increase in turret diameter or speed also leads to an increase in the centrifugal forces on the materials to be compressed. Another limiting factor: customers prefer more compact machines because of the high cost of cleanroom space.

Maximum Productivity, Minimum Footprint

At Interpack 2014, with the FE75, Fette Compacting presented a machine that offers both high productivity and a small footprint. The machine is the third model in the innovative FE Series, which was developed completely from the ground up. The FE75 shares a number of outstanding technological features with the other two machines of the FE Series, such as a new, patent-pending conical filling unit, highly accurate manually adjustable filling table, innovative compression rollers, trouble-free tablet discharge through the column as well as a new operating terminal and the connection of process equipment through a standardized plug-and-play interface. While the FE35 single-sided rotary press is optimized for quick changeovers and the FE55 offers maximum flexibility in diverse production scenarios, the FE75 has been specifically tailored to large batch production with high-volume output. 

The success of this design is made impressively clear by the performance data of the new machine. With a footprint of just two square meters, the FE75 is the only double-sided rotary press of its size that enables users to press single- and double-layer tablets as well as powder. The FE75 configuration with FS12 punches and 115 punch stations achieves a maximum output of over 1.6 million tablets per minute. The four compression stations enable users to work with two intermediate pressures and process materials that are difficult to compress. Using FS19 punches even facilitates up to 166 percent longer dwell time in direct compression.

Design Details: Minimum Product Loss, Protection against Contamination and Optimum Vibration Dampening

Fette Compacting’s development department has also successfully improved many details. For example, new pneumatically controlled tablet scrapers make a significant contribution to efficient tableting. Now fitted as standard, they guarantee a constant surface pressure and minimize product loss. New conical filling units also make it possible to easily and safely process complex product mixtures. Tablet contamination is hindered by a new lubrication system that separates the lubrication of punch head and punch shaft in combination with a closed cam track system. Another innovative feature is the design of the FE75 chassis. Optimum vibration dampening is provided by a two-part frame structure and a pneumatic suspension system in the feet under the housing made of FDA-certified high-performance plastic that is already known from the FE55 and FE35.

TRI.EASY Design: Simple Operation Delivers Efficiency

Fette Compacting has also implemented its new TRI.EASY design concept in the FE75. It is based on the principle that technology can only be efficient if it is equally easy to use in the three dimensions of production, changeover and maintenance. That’s why the TRI.EASY design focuses on the user and ensures trouble-free production irrespective of the operator’s experience and qualifications.

Fette Compacting has implemented a new approach to turret changing. Utilizing a patent-pending process, the turret is raised by a lifting mechanism employing the adjustment drive of the compression rollers and then moved out of the machine with the aid of a CFRP carrier support. All the work steps involved in turret changeover have been automated or designed for tool-less execution. In addition, all the machine’s supply lines are connected by multifunctional plugs. The machine’s design also delivers excellent accessibility to all components.

Another highlight of the FE75 is its new extraction unit. It has a completely tubeless design. Fixed positioning makes it practically impossible to falsely install the unit. The advantage for users is clear: faster and easier fitting and changeover during cleaning.