Xpress – Tableting Range | 11

Packaging Technology

Xpress – Tableting RangeManesty – Xpress 300 | Xpress 500 | Xpress 700

2 | Xpress – Tableting Range

The Xpress range has been designed to facilitate flexible batch production. It is easy to use and at the same time provides excellent tableting results. With the introduction of a number of innovative features such as the stepped cabinet design and rapid product changeover these features allow customers to immediately access the upper and lower compression zones and reduce down time without the need to dismantle mechanical parts.

Xpress Tableting Range with mpower –Integrated Technology from Manesty

Manesty’s highly successful Xpress range of tablet compression machines consists of the Xpress 300, Xpress 500 and Xpress 700. Customers now benefit from increased production flexibility to run small, medium and large batch sizes on both single and double-sided presses. Each was designed with ease of use in mind and each machine offers many unique advantages.

▶ Quiet and vibration free operation▶ 100Kn compaction force capability for the first and second

compression stages▶ Soft start to avoid rejects at start of production▶ Graduated feeder support pillar to allow easy and accurate

feeder adjustment▶ WiP solution available

▶ Novel effervescent and bi-layer production▶ Integrated turret removal system enables increased output

and ability to change tooling configuration from B to D▶ The compaction force measurements method introduced

with mpower control system provides fast and accurate reporting of data with predictive capabilities

▶ Compliant with cGAMP and FDA 21 CFR Part 11 guidelines

Key benefits Xpress range

Manesty has also focused on the ergonomics of the machine. The Xpress range benefits from a compact footprint with integrated electrical and pneumatic controls to minimise the use of floor space and installation work. This compact design in addition to the air cushion enables customers to easily move the machine to another area without the use of non GMP equipment such as pallet or fork lift trucks.

Xpress – Tableting Range | 3

Manesty’s Xpress 700 offers customers an exceptional system. Featuring automatic weight control of each layer and complete segregation of different materials, tablets produced will be free from cross contamination and have a clearly defined demarcation line between layers. All sampling and setting of each layer’s parameters are set via the control system. This conversion from a single layer version to a bi-layer version can be achieved quickly and easily. A single

▶ Precise independent monitoring of each layer by a unique algorithm▶ Special air jets to prevent cross contamination between layers▶ Recipe driven first layer sampling system▶ Clear demarcation between layers▶ Fast conversion from bi-layer to single layer production▶ High yields guaranteed

Additional key benefits for bi-layer production

layer press can be converted to the bi-layer version at any time in the future by means of a retrofit conversion kit.

4 | Xpress – Tableting Range

Xpress tool free turret removal system

With all pressure rolls in the open position, access to remove punches and dies in a conventional way is unrivalled. The machine turret can also be easily removed without the need to open cam tracks or remove an extensive number of components. Proven product to product changeover time in less than one hour.

Unique removable seal plates fitted as standardThis feature significantly reduces the cleaning and the need to replace punch scraper seals. The upper and lower seal plates are made of stainless steel and can be fully immersed in water or placed in a washing machine.

Faster Product Change Over

Flexibility to produce different batch sizes efficiently is important in meeting current and future production demands. To assist in fulfilling this requirement, Manesty’s Xpress range offers an impressively fast turret exchange system. This tool free operation reduces product change over dramatically. The stepped cabinet design offers for the first time the possibility of accessing the upper and lower part of the compression zones without the need for tools. Access to the turret when removing punches and dies can be achieved in less than three minutes. A specially designed stainless

steel trolley is used to safely move the turret, punches and cams to the cleaning room.

▶ Stepped cabinet design allows fast access to the turret for conventional product changeover

▶ Quick release components dramatically reduce the dismantling and re-assembling times

▶ The hopper is removed from the inside of the press for the first time

▶ Reduced sized pillars enable more user friendly access

▶ Compression rolls are swivelled open using handles to simplify the access to the turret

▶ Recipes are used to speed up the set-up times at the start of production

▶ Integral turret removal system negates the need to store extra equipment outside the press

Key benefits

Xpress – Tableting Range | 5

Manesty Zero Clearance Feeder

▶ Unique paddle configuration provides total control of volume and product flow to the die

▶ No requirement to re-circulate material around the turret which minimises product contamination

▶ Product loss minimised due to the elimination of the scraper blade

▶ Final paddle design avoids “packing” of fine materials

▶ Excellent weight consistency over a wide range of tablet outputs

▶ Choice of seal options to suit a wide range of substrates▶ Graduated positioning of feeder for faster, easier and

reproducible set-up▶ Tool free dismantling▶ Parts can be fully immersed in water

Key benefits

Unique to Manesty, the lower punch is pulled down straight after the powder- feeding phase to prevent loss of material on upper punch entry.

Our proven three-paddle configuration offers customers the flexibility to tablet an extensive range of materials in the die. The feeder is mounted on a single column with calibrated height adjustment which allows the settings to be reproduced. Feeder gauges that measure the distance between the feeder and the die table are no longer required. A quick release mechanism ensures rapid removal for cleaning and significantly reduces set up time.

The zero clearance feeder design has been proven to excel in maintaining consistent weight uniformity at a wide range of press operating speeds, whilst achieving yields well over 99%. This capability is maintained whether wet granulation or direct compression formulations are used.

▶Standard feeder seal

▶▶Polyurethane seal (optional)

6 | Xpress – Tableting Range

mpower Control Technology

Single point of interfaceThe mpower control system provides the user with a single point of user interaction through its touch screen. All machine adjustments are made here. mpower allows the Xpress to be run with the minimal user input and makes automatic operation possible.

Recipe drivenThe recipe-based approach allows one-touch setting of all machine parameters for eachformulation. This ensures fast setup and swift product changeover.

Flexible reportingThe Xpress reporting package allows for tailored and detailed batch reporting. This includes detailed compression data, online sampling analysis, rejected tablet details, all machine adjustments, product information, machine event log and alarms. Dedicated processing within the machine software modules allows for instant control and a higher level of data acquisition than was previously possible. While each tablet can be compressed in < 10ms, up to 70 force measurements can be performed per compres-sion. All process and key mechanical functions are alarmed, ensuring the highest standards of security for both the operator and product.

Standard platformThe Microsoft Windows operating system provides a robust platform and familiar environment for system administration. Along with protection from integral UPS, this ensures a high level of security for system and machine data. Remote access software provides diagnostic capabilities at site, and the OPC link allows for data transfer to higher-level systems. Disk imaging software offers a secure and fast solution for system and data backups.

Highly configurableThe Xpress Configuration program gives mpower a common interface across the full range of Xpress machines and covers all options. The Xpress User program provides for complete user management. Machine access can be tailored on an individual basis.

mpower integrated control technology provides for the control and powered adjustment of all the main press parameters and acts as the means of communication to ancillary equip-ment. A user friendly Windows XP based operator interface allows quick and intuitive operation and enables the press to be used

with the minimum of specialist training.

▶ Intuitive operation▶ In-house design and support▶ Full audit and validation support▶ Features and guidance for 21 CFR Part 11 compliance▶ Communication to MES▶ Ancillary equipment interfacing▶ Unique weight control for bi-layer tablets

Key benefits

1 Accuracy: Weight Thickness and Hardness unit. For in process measurement and feedback to the Xpress tablet press.

2 Balance: The new Manesty Autoweigh provides measurement and feedback to the Xpress tablet press of the actual tablet weight.

3 Bulk hopper: To provide controlled feed to the Xpress 700 from a customers ibc (Intermediate Bulk Container).

4+5 Tablet dedusting: Combined deduster and metal detector. Flexible height gaining tablet deduster with easy clean features and optional metal detector.

6+7 Tablet collection systems: To allow collection of good tablets, with or without attended opera-tion. To distribute product into containers mounted on a pallet to minimise floor space requirements.

Options

41 2 3

5 6 87

8 Turret removal system: To provide a means of locating, securing and transporting removed or clean turrets from the Xpress range.

Maintenance Maintenance engineers demanded improved access to maintenance points, clear procedures for planned downtime, on-line testing and calibration capabilities. Maintenance access has been optimised with large openings on all four sides to the mechanical zone. With complete segregation between the production and mechanical zones and all dust extraction routed via the roof, no product or dust can enter the mechanical zone. The temperature of the mechanical zone is monitored for safe operation. The mpower control system provides on-line testing for press functions as well as one touch calibration facilities.

Xpress – Tableting Range | 8

Technical Data

16

23

Stations

Stations

Stations

Xpress 300

Xpress 500

Xpress 700

22

32

24

27

49

30

39

61

35

50

73

39

81

Punch Type D/EU1 D/EU1 D/EU19 D/EU19 D/EU19 D/EU19

Die Type D D B B BB BBS (22 mm O/D)

Maximum Tablet Diameter 25 mm 25 mm 16 mm+ 16 mm+ 13 mm+ 11 mm

Tablet output / hour Minimum 9,000 10,500 12,000 15,000 18,000 19,500

Tablet output / hour Maximum 114,000 157,500 172,500 216,000 252,000 280,500

Max. 1st compression force 100 kN 100 kN 100 kN 100 kN 100 kN 100 kN

Max. 2nd compression force 100 kN 100 kN 100 kN 100 kN 100 kN 100 kN

Maximum filling depth 21 mm 21 mm 18 mm 18 mm 18 mm 18 mm

Punch Type D/EU1 B/EU19 B/EU19 B/EU19

Die Type D B BB BBS (22 mm O/D)

Maximum Tablet Diameter 25 mm 16 mm+ 13 mm+ 11 mm

Tablet output / hour Minimum 36,000 45,000 54,000 60,000

Tablet output / hour Maximum 528,000 657,500 786,000 1,008,000

Max. 1st compression force 100 kN 100 kN 100 kN 100 kN

Max. 2nd compression force 100 kN 100 kN 100 kN 100 kN

Maximum filling depth 21 mm 18 mm 18 mm 18 mm

Punch Type D/EU1 D/EU1 D/EU19 D/EU19 D/EU19

Die Type D D B B BBS

Maximum Tablet Diameter 25 mm 25 mm 16 mm+ 16 mm+ 13 mm

Tablet output / hour Minimum 12,000 16,500 13,500 19,500 24,000

Tablet output / hour Maximum 165,000 229,500 193,500 280,500 360,000

Max. 1st compression force 100 kN 100 kN 100 kN 100 kN 100 kN

Max. 2nd compression force 100 kN 100 kN 1 00 kN 100 kN 100 kN

Maximum filling depth 21 mm 21 mm 18 mm 18 mm 18 mm

+ Larger tablets possible using shaped tooling.NB Actual tablet output and maximum application of compaction force will depend upon the materials being compressed and the size and shape of punches respectively.

+ Larger tablets possible using shaped tooling.NB Actual tablet output and maximum application of compaction force will depend upon the materials being compressed and the size and shape of punches respectively.

+ Larger tablets possible using shaped tooling.NB Actual tablet output and maximum application of compaction force will depend upon the materials being compressed and the size and shape of punches respectively.Outputs tested using ISP Placebo Formulation.

Technical specifications are subject to change without notice.

9 | Xpress – Tableting Range

Specifications

1505 1505

737

grou

p

671

ssr

1125

658658

2150

Chute removal

allow 500

Chute removalallow 500

195group

269SSR

2186

120

2342

front of machineright hand side of machine left hand side of the machine

chute removal

allow 500 mm

1151 1326170

647 647

1128

2122

740

SSR269 SSR

110group

883

grou

p

2150

2164

front of machineright hand side of machine left hand side of the machine

Chute removal

allow 500 mm

1037 647647

1125

1701037

2150

658

SSR

724

grou

p

272.5SSR

215 group

2216 21

27

front of machineright hand side of machine left hand side of the machine

Xpress 300 – compact, flexible & strongSuitable for small to medium batch sizes and following the same phi- losophy as the other presses in the range with 100 kN first and second stage compression capability. The sophisticated Xpress 300 aims to deliver the lowest cost of owner- ship benefits by maximising yield, flexibility, productivity and reliability.

Xpress 500 – consistency, yield & flexibilityWith an exceptional output capacity for a single sided tablet press, the Xpress 500 provides compression solutions for a wide range of applications. The stylish Xpress 500 reflects and meets the regulatory, operational flexibility and cost of ownership challenges demanded by our customers.

Xpress 700 – new generation double-sided tablet pressProviding the option for bi-layer production if required and the flexibility of removable turret technology, the impressive Xpress 700 combines a high level of performance coupled with high output capability. Reliability and cost effectiveness comes as standard.

No separate electrical cabinet required!

Keyboard drawer

Handle

Serviceconnections

Brakedcastors

Drawer front �ipsdown

front elevation lefthand side elevation

Key

boar

d98

4

1322

Scr

een

1605

700 620

1301

105.5

322

Control Commons

Technical specifications are subject to change without notice.

Bosch Packaging Technology Ltd.

Kitling Road Knowsley Merseyside, L34 9JS Great BritainPhone +44 (0) 151 547 8000Fax +44 (0) 151 547 8001www.boschpackaging.comInfo.packaging-kny@bosch.com

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