Leitz Metalworking Technology Group

2090 WiP tablet pressReliable washability

Maximum productivitySingle rotary press

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A significant reduction in the downtimeinvolved in product changeover is an outstanding feature of all FETTE's WiPtablet presses.

Of equal importance, further-more, is the great reduction inworkplace pollution, in particu-lar when highly active granu-lates are being compressed. Inthe 2090 WiP, we at FETTEhave transferred our washingtechnique, widely acceptedwithin this sector of industry,to our widely available singlerotary press. The washing procedure is fullyintegrated into the automatic control system,and can be adapted for specific products.

The 2090 WiP makes this modern tabletpress with this extended range of functionsavailable on the world market. The new andinnovative features that have been integratedconfirm its leading position.

Ideal washability at highest

reliability.

Feature Summary:2090 WiP Tablet Press

The key features:

■ Washable compression compartment– No internal shrouds or covers– Two identical compression stations– Up to 324,300 tablets/hour output– Exchange of the complete turret, including

punches, dies and cams– Automatic turret locking and unlocking– Full process automation– Automatic proportioning lock– Automatic emptying of the Fill-O-Matic– Complete rinsing of the compression

compartment

Your benefit:

■ Automatic pre-washing■ Easier access to the compression

compartment■ Smooth, stainless steel surfaces■ Efficient batch production■ Rapid product and format changeover, even

with toxic products, resulting in higher annualyields

■ Reduced down-time■ 24 hour lights-out production■ Dust is wet down before the press is opened■ Final cleaning can be validated

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Washability – 2090 WiP

Precisely engineered wash system

■ Washing system with stainless steel pipes in all4 support pillars

■ A total of 11 washing nozzles■ Nozzles divided in 6 pulsed washing groups■ Complete rinsing of the compression area

Designed for reliable function

■ Compression area is watertight and dust-proof■ No internal shrouding to obstruct cleaning■ Majority of components in the compression

area are constructed with rust-proof material■ Upper and lower compression areas are stain-

less steel with automatic drain valve■ Machine exterior is smooth for easy cleaning

Flexible washing programs

■ Washing procedure specific to the product■ Optimized cleaning for fast product changeover■ Washing programs can be programmed with the

following:– Washing (with foam)– Soaking– Normal rinsing– Rinsing with de-ionized water– Air drying

■ 3 washing programs (programs A and B for thetablet press, C for the peripheral devices) canbe stored for each product

Specially designed cleaning equipment

■ WiP Center cleaning equipment with flexibleconnections to the 2090 WiP

■ Stainless steel housing ■ Pump unit for cold water (40°C) and for hot de-

ionized water at up to 80°C■ 2 different cleaning agents can be added■ Foam cleaning possible■ Controlled by the 2090 WiP’s PC■ Connection to WiP-compatible peripheral equip-

ment■ Monitoring of process-relevant functions■ Frequency-controlled pump for 50 or 60 Hz■ All pressure valves fitted with feedback sensors

for the safety of the washing process■ Two machines may be connected to one wash

center – washing is carried out in sequence 5

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Productivity – 2090 WiP

Superior performance

■ More than 300,000 tablets/hour■ 24 hour lights-out production

Reliable control:

■ Decentralized computer logic■ Direct control and regulation of all the machine’s

motor-driven adjustments■ Acquisition of data from all measuring sensors■ High-speed data transfer to the operator inter-

face via Ethernet TCP/IP■ Clearly structured control loops■ Extremely reliable control system■ Incorporation of process specific data into

control process■ Sensors and measuring instruments designed

redundantly and with high sensitivity ■ Precise single ejection via accurate detection of

high compression forces

■ Simple integration into production lines■ Maximum format flexibility

Tablethardness

Control circuits

1 = Compression force control2 = Weight control3 = Hardness control

Tabletweight

Cylindricalheight

Fill depth

Comp. force

Nominal value

1 2

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Nominal value

Nominalvalue

Modular system:

■ 2090 WiP tablet press with interchangeableturret

■ Control cabinet with VME Bus computer■ Operator and analysis unit■ Peripheral devices

– GRATEX (tablet dedusting and deburring)– CHECKMASTER (in-process checking of

tablet weight, thickness and hardness)– LOADING CENTER (tablet discharge)

Detailed documentation:

■ All operator changes completely documented(change record)

■ Process data communication (productionrecord/result record)

■ Operating state documentation (diagnosticrecord)

■ Summary with automatic analysis■ Batch records

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Flexibility – 2090 WiP

Rapid Turret changeover

■ Extremely fast turret changeover facilitated by:- Automatic central gear to engage and

disengage the die table- Automatic centering on the thrust bearing- Removal with tools and cams intact

■ Large window flaps allow access from all sidesof the machine

■ Cantilevered turret unit mounting ■ User friendly operation through step-by-step

menus with confirmation function■ Automatic unlocking and locking of the propor-

tioning stations

Turret

■ Completely washable■ Turret and punches made from stainless steel ■ Most cams made of plastic

- for reduced noise emission- for reduced weight- no corrosion

Intelligent multi-function connecting arm

■ Multi-function connecting arm integrating:- cam track fixing arm, including punch

tightness measurement■ Mounting for tablet take-off bar and pneumatic

reject■ Integrated lubrication supply and distribution

system for punch lubrication

Newly developed feeder base plate:

■ Product scraper can be made of POM, bronzeor titanium

■ New feeder base plate with closed channeldesign for minimized loss

■ Easily changed sealing segments for differenttablet sizes and shapes

■ Separate scraper not required■ Pre-filling not required■ Plastic cover with different designs■ Fitted to the feeder base without tools■ Can be made from V4A (AISI 316) steel or

aluminum■ Integrated mounting for product wiper

Mechanics – 2090 WiP

Precise dosing cams:

■ Dosing cams automatically lock with precisioncontrol

Easy disassembly:

■ Very few parts to be removed for separatecleaning when changing product

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Ergonomic control panel

■ 15" touch screen ■ Powerful Pentium industrial PC■ CD ROM drive■ Windows NT operating system■ Uninterrupted power supply■ HP color inkjet printer■ Computer-controlled, patented height adjust-

ment

Operation and Control– 2090 WiP

Specially designed control cabinet

■ Stainless steel V2A (AISI 304)- smooth surfaces- GMP compliant- integrated plugs- see-through doors for diagnosis from outside- cooling system with hermetically sealed

component area■ Safety PLC■ CAN bus■ VME Bus control computer with Motorola CPU■ Ethernet TCP/IP communication to the opera-

tion panel■ Easily accessible, clearly arranged components■ Integrated modem for remote Teleservice

Structure – 2090 WiP

Modular mechanical design

■ Maximum precision, even under stress:- static,- dynamic- thermal

■ optimized stability (FEM calculation)■ maximum operating reliability■ maximum working safety■ enclosed compression area (noise/dust)■ no cross-contamination■ extended maintenance intervals■ modular design with separation into four sec-

tions:■ upper section

- upper section- compression compartment- middle area- drive area

Middle section

■ precision mounting of the turret■ turret and turret shaft frictionally engaged and

form-fitting ■ maintenance-free servo motors used for all

adjustments

Drive area

■ suspended base plate with vibration insulation■ main drive supported by torque rest ■ turret shaft is stabilized by precisely tapered

roller bearings

Compression compartment

■ all compression stations have the same con-struction

■ pre-compression and main compression forceup to 100 kN possible

■ pre-compression and main compression rollersare identical

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Containment Packagefor WiP presses

Contents of the containment package:

■ Manual spray gun in the compression compart-ment

■ Manual dust extraction nozzle in the compressi-on compartment

■ An RTP (rapid transfer port) interface fordischarge of tablets to the isolator

■ Second RTP provides a means for tools to beintroduced (acts as a material lock)

■ Optional clean room air valve with controlsystem – to protect the clean room air systemfrom cross contamination in the event the dustextraction system malfunctions

■ 5 large, oval glove ports on three window flaps■ If required, a special valve can be fitted for

clean-room air feed, with a control system in theair supply to safely provide the pressure diffe-rence if the evacuation fails, including alarmsignal

■ Contamination-free material feed through theGlatt SKS smooth isolation flap system SKS DN100 or DN 200, recommended by FETTE

■ The WiP presses are fitted with a WiP-Center,stainless VA-steel turret and stainless VA-steelFOM as standard

Toxic materials used in tablet production cancontaminate the workplace, particularly whendust is released from the press and peripheralequipment during product changeovers. Thispresents significant health risks to the operators.The introduction of WiP technology (Wash-in-Place) is the first step in reducing contaminationhazards.

Containment of the WiP presses, along with the asso-ciated peripheral devices, brings cutting edge safetytechnology to the industry. Near zero emission clea-ning procedures allow for faster, safer, more conveni-ent, product changeovers.

Secure separation with RTPs(Rapid Transfer Ports):

■ RTPs are double-cover containers for toxicproducts, working according to the principles ofan airlock- there is a safety interlock for opening the lock- RTP interface for tablet discharge- tablet discharge is enclosed within an isolator- RTP equipment for introducing tools- RTP interface between isolator and tablet

press permits safe separation■ The RTP is closed from the inside using the

gloves■ The advantage of this is that only the non-

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Secure granulate feed through the smooth flap system:

■ The system ensures fully sealed transfer of thegranulate from the container to the press

■ SKS DN 200 and DN100 smooth flap system:- efficient docking system, capable of

automation, for filling the press with onecontainer

- operates reliably for low-dust producthandling

- prevention of cross-contamination- observation of standards and conditions- reduction of necessary secondary measures

to achieve containment- minimization of clean-room spaces- reproducible containment over a long period

of time- PLC controller for docking and for

opening/closing the flap- FETTE controller provides signals to the flap

system- the entire compression compartment is

cleaned, and is supplied with liquid from theFETTE WiPCenter

- inflatable seals at the active flap

■ Functioning of the smooth flap system- consists of two halves that can only be

opened when the two halves are latchedtogether

- active flap at the docking station withpneumatic drive for locking and foropening/closing

- passive flap on a moving part (e.g. container)is controlled by the active flap

- the surface only comes into contact eitherwith the product or with the environment, sothere is no cross-contamination

Peripheral equipment that may be used withcontainment:

■ Isolator with RTP interface – e.g. from Carlisle■ WiP vertical de-duster■ Containment vertical de-duster with metal

check■ Weightmaster 4.1 IP67■ Gratex IP65■ Hamo washing centre

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Glove ports for manual operation:

■ Ergonomic design and the presence of severalports ensure that the entire compression compart-ment can be reached- external and internal covers, and intermediate

seal- double sealing for contamination-free glove

exchange- wiring for glove ports in the window flaps

■ Glove port operation- the outer cover is opened by means of a hinge- the glove is between the covers- the inner cover is removed, and suspended from

a mounting on the pillar- as the inner cover is opened, a sensor stops the

press- when leaving, the inner cover is closed with the

glove from outside- glove is between the covers during pressing

contaminated side of the cover ever faces theoutside

■ Hollow section seal between window flap and RTP

Number of stations 47 43 36 29 29 22

EU 19 EU 19 EU 19 EU1“Punch type

(IPT/TSM 19) (IPT/TSM 19) (IPT/TSM 1“) EU 1“-441 EU 35BBS BB B D

Tablet output/h min. 42.300 38.700 32.400 26.100 26.100 19.800

max. 324.300 296.700 248.400 174.000 174.000 105.600

MMax. compression kN 100(1) 100 100 100 100 100

Max. pre-compr. force kN 100(1) 100 100 100 100 100

Max. tablet diameter mm 11 13 16 25 25 34

Max. filling depth mm 18 18 18 18 18 18 (22)

Max. tablet thickness mm 8,5 8,5 8,5 8,5 8,5 8,5(10,5)

Pitch circle diameter mm 410 410 410 410 410 410

Die table rotation speed min1 15-115 15-115 15-115 15-100 15-100 15-80

Die diameter mm 22 24 30,16 38,1 38,1 52

Die height mm 22,22 22,22 22,22 23,8 23,8 30

Punch shaft diameter mm 19 19 19 25,35 25,35 35

Punch length mm 133,6 133,6 (133,35) 133,6 (133,35) 133,6 (133,35) 133,6 133,6

Upper punch pen. depth mm 1-4 1-4 1-4 1-4 1-4 1-4

Weights Tablet press approx. 3500 kg · Operator terminal 100 kg · Electrical cabinet 350 kg

Power supply data Operating voltage 220-500 V, 50/60 Hz · Total fusing 35 A/6 · Power consumption 13 kW

Cold water connection max. 40° · 2-4 bar · min. 60 l/min

Hot water connection max. 80° · 2-4 bar · min. 60 l/min

Drainage water min. NW 50 mm

Compressed air connection 6-10 bar · 300 l/min

(1) Tools only permit up to 70 kNIf tools are large and filling depth is high the press cannot be run at the top speed.

Technical Data – 2090 WiP

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Space requirements – 2090 WiP

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