INTEGRATED APPARATUS FOR TABLET MANUFACTURING AND PACKAGING

Abstract

An innovative pharmaceutical machine 100 integrates tablet melting 101, punching 102, coating 103, and packaging 104 processes. The machine comprises a melting chamber 105, a punching unit 106, a coating apparatus 107, and a packaging module 108. A microprocessor 109 controls the integrated processes, ensuring precision and efficiency. The machine features adjustable temperature control 110, interchangeable punch dies 111, a spray coating system 112, and a sealing mechanism 113. This invention improves the efficiency of the pharmaceutical tablet production process, thereby saving more time and labor and improving quality and consistency.

Specification

Description:The following is a step-by-step description of the invention, detailing the components, and their functionalities mentioned below:
The novel tablet melting, punching, coating, and packaging machine for pharmaceuticals is an integrated system designed to streamline the tablet production process. This detailed description will elaborate on each component and its function within the overall system.

1. Overall Structure 100: The machine consists of a main frame 114 that houses all the components in a logical, sequential order. The frame is constructed from stainless steel to meet pharmaceutical-grade hygiene standards. The overall dimensions are approximately 2.5m x 1.5m x 2m, making it compact enough for most laboratory or small production environments.

2. Melting Chamber 105: The melting chamber 101 is located at the start of the production line. It is a double-walled, insulated container with a capacity of 5 liters. The chamber is equipped with:

- Temperature control system (110): This system uses Platinum Resistance Thermometers (PRTs) for accurate temperature sensing and solid-state relays for precise heat control. It can maintain temperatures between 30°C and 300°C with an accuracy of ±0.5°C.
- Stirring mechanism (115): A variable-speed impeller ensures uniform heating and mixing of the melted material.
- Material feed system (116): An automated hopper feeds raw material into the melting chamber as needed.

3. Punching Unit (106): The punching unit 102 is positioned directly below the melting chamber. It features:
- Interchangeable punch dies (111): A set of quick-change dies allows for easy switching between different tablet shapes and sizes.
- Pressure control system (117): Hydraulic pressure can be adjusted between 1 and 100 kN to accommodate different material properties.
- Ejection mechanism (118): A pneumatic system ejects formed tablets onto a conveyor belt leading to the coating apparatus.

4. Coating Apparatus (107): The coating system 103 utilizes a novel spray coating technology:

- Spray system (112): Multiple precision nozzles create a fine mist of coating material, ensuring even coverage.
- Tablet bed (119): A perforated, vibrating bed keeps tablets in constant motion during coating.
- Drying system (120): Warm, filtered air is circulated to quickly dry the coating.

5. Packaging Module (108):
The packaging unit 104 completes the production process:
- Counting mechanism (121): An optical sensor accurately counts tablets for packaging.
- Sealing mechanism (113): Heat-sealing technology creates airtight blister packs or pouches.
- Labeling system (122): An integrated printer applies batch numbers and expiration dates.

6. Microprocessor Control System (109): The central microprocessor 109 is the brain of the operation:
- User interface (123): A touchscreen display allows operators to input parameters and monitor the process.
- Process control algorithms (124): Advanced software optimizes each stage of production.
- Data logging (125): All process parameters are recorded for quality control and regulatory compliance.

7. Material Handling System (126): A series of conveyor belts and chutes move tablets between stages:

- Enclosed design (127): Prevents contamination during transfer.
- Speed control (128): Adjusts to match the production rate of each stage.

8. Cleaning System (129): An automated cleaning system ensures hygiene between production runs:
- Spray nozzles (130): Deliver cleaning solutions to all product-contact surfaces.
- Waste collection (131): Collects and disposes of cleaning residues.
Embodiments
1. Basic Model (200)
- Includes all core components 101-109
- Suitable for small-scale production or research labs
2. High-Capacity Model (300)
- Enlarged melting chamber 301 with 20L capacity
- Dual punching units 302 for increased output
- Extended coating bed 303 for longer coating times
3. Multi-Product Model (400)
- Multiple melting chambers 401, 402, 403 for different materials
- Rotary die system 404 for quick product changeovers
- Modular coating apparatus 405 for different coating types
4. Continuous Production Model (500)
- Continuous feed melting system 501
- Roll-compaction punching unit 502
- Continuous coating drum 503
- In-line packaging system 504
5. Miniaturized Model (600)
- Compact design for benchtop use
- Reduced capacity (1L melting chamber)
- Manual material handling between stages
6. Advanced Analytics Model (700)
- Integrated spectroscopic analysis 701 for real-time quality control
- Machine learning algorithms 702 for process optimization
- Remote monitoring and control capabilities 703
7. Sterile Production Model (800)
- Integrated HEPA filtration system 801
- UV sterilization between stages 802
- Isolator-compatible design 803
8. Eco-Friendly Model (900)
- Energy-efficient heating systems 901
- Water-based coating system 902
- Biodegradable packaging options 903
Operation
1. Raw material is fed into the melting chamber 105 through the material feed system 116.
2. The temperature control system 110 heats the material to the specified temperature while the stirring mechanism 115 ensures uniform melting.
3. Melted material flows into the punching unit 106, where it is formed into tablets using the selected die 111.
4. Formed tablets are ejected onto a conveyor belt and moved to the coating apparatus 107.
5. Tablets are coated using the spray system 112 while being agitated on the tablet bed 119.
6. Coated tablets are dried and then transferred to the packaging module 108.
7. Tablets are counted, packaged, and labeled.
8. The microprocessor 109 monitors and controls all stages of the process, adjusting parameters as needed.
This integrated system significantly reduces production time, minimizes contamination risks, and improves overall efficiency in pharmaceutical tablet production.
Method of Performing the Invention
The optimal method for operating the novel tablet melting, punching, coating, and packaging machine involves careful calibration and synchronization of all components. Here's a step-by-step guide to achieve the best results:
1. System Initialization:
- Power on the machine and allow the microprocessor 109 to perform a self-diagnostic check.
- Ensure all components are clean and sterilized using the automated cleaning system 129.
2. Material Preparation:
- Load the raw material into the material feed system 116.
- Input the material specifications and desired tablet parameters into the user interface 123.
3. Melting Process:
- The microprocessor 109 will calculate and set the optimal melting temperature based on the material properties.
- Initiate the melting process. The stirring mechanism 115 should be set to a speed that ensures uniform heating without introducing air bubbles.
4. Punching Operation:
- Select and install the appropriate punch die 111 for the desired tablet shape and size.
- The microprocessor 109 will adjust the pressure control system 117 based on the material properties and tablet specifications.
- Begin the punching process, monitoring the tablet formation rate and quality.
5. Coating Application:
- Prepare the coating solution and load it into the spray system 112.
- Set the tablet bed 119 vibration frequency to ensure even tablet movement.
- Initiate the coating process, allowing the microprocessor 109 to control the spray rate and duration.
6. Drying and Curing:
- Adjust the drying system 120 parameters based on the coating type and environmental conditions.
- Allow sufficient time for proper curing of the coating.
7. Packaging:
- Ensure the appropriate packaging materials are loaded into the packaging module 108.
- Set the counting mechanism 121 to the desired tablet count per package.
- Initiate the packaging process, monitoring for any irregularities.
8. Quality Control:
- Regularly sample tablets from each stage of the process for quality checks.
- Utilize the data logging feature 125 to review process parameters and identify any deviations.
9. Cleaning and Maintenance:
- After each production run, activate the cleaning system 129 to thoroughly clean all product-contact surfaces.
- Perform regular maintenance checks as outlined in the machine's manual.
, Claims:1. A pharmaceutical tablet production machine 100, comprising:
? a melting chamber 105 with temperature control 110;
? a punching unit 106 with interchangeable dies 111;
? a coating apparatus 107 with a spray system 112;
? a packaging module 108 with a sealing mechanism 113; and
? a microprocessor 109 configured to control and synchronize operations of the melting chamber, punching unit, coating apparatus, and packaging module;
wherein said machine integrates tablet melting 101, punching 102, coating 103, and packaging 104 processes in a single unit.
2. A method of producing pharmaceutical tablets, comprising the steps of:
? melting raw material in the melting chamber 105;
? forming tablets in the punching unit 106;
? coating the tablets in the coating apparatus 107; and
? packaging the coated tablets in the packaging module 108;
wherein all steps are controlled and synchronized by the microprocessor 109.
3. The system as claimed in claim 1, further comprising:
a material handling system 126 with enclosed design 127 and speed control 128;
a cleaning system 129 with spray nozzles 130 and waste collection 131.
4. The system as claimed in claim 1, wherein the melting chamber (105) comprises:
a double-walled, insulated container;
a stirring mechanism 115;
a material feed system 116.
5. The system as claimed in claim 1, wherein the punching unit (106) comprises:
a pressure control system 117;
an ejection mechanism 118.
6. The system as claimed in claim 1, wherein the coating apparatus (107) comprises:
a tablet bed 119;
a drying system 120.
7. The system as claimed in claim 1, wherein the packaging module (108) comprises:
a counting mechanism 121;
a labeling system 122.
8. The system as claimed in claim 1, wherein the microprocessor (109) comprises:
a user interface 123;
process control algorithms 124;
a data logging system 125.
9. The system as claimed in claim 1, wherein the machine is configurable as a high-capacity model (300) comprising:
an enlarged melting chamber 301;
dual punching units 302;
an extended coating bed 303.
10. The system as claimed in claim 1, wherein the machine is configurable as a multi-product model (400), (700) comprising:
multiple melting chambers 401, 402, 403;
a rotary die system 404;
a modular coating apparatus 405;
integrated spectroscopic analysis 701;
machine learning algorithms 702; and
remote monitoring and control capabilities 703.

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