Coatings Durability, Productivity, Longevity. - I...

PharmaCote®

Durability, Productivity, Longevity.

Includes New

PharmaCote ® Coatings

MKT-01 Issue 10

PharmaCote Issue 10.indd 1 28/01/2014 10:57:38

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Description Page

Introduction 4

TSAR Project 5-6

PharmaCote® HC (Hard Chromium) 8

PharmaCote® HC+ (Hard Chromium Plus) 9

PharmaCote® EC (E-Chrome) 10

PharmaCote® CN (Chromium Nitride) 11

PharmaCote® CN+ (Chromium Nitride Plus) 12

PharmaCote® CT (Textured Chromium Nitride) 13

PharmaCote® CX (Chromium Nitride Extra) 14

PharmaCote® CX+ (Chromium Nitride Extra Plus) 15

PharmaCote® TN (Titanium Nitride) 16

PharmaCote® RS (Resilient Surface) 17

PharmaCote® DN (Dymonic Coating) 18

PharmaCote® PI (Polymer Insert) 19

TSAR≈PREDICT 20

Coating Summary 21

Corrosion Resistance Table 22

Hardness Table 23

Comparison Table 24

PharmaCote® Automated Polishing Guide 25

MF Automated Polisher 26

PharmaGrade® Steels 27

MKT-01 Issue 10

Contents




Coating technology backed by researchPharmaCote, improving performance, reducing costs

The original and still the market leader; our range of coatings, combinedwith continued research, enables us to offer you the right coating foryour application.

PharmaCote, we already have the answers

Visit www.iholland.co.ukor telephone +44 (0) 115 972 6153

IHPharmacote267x197_Layout 1 14/08/2012 14:17 Page 1

ANTI-STICK

ANTI-ABRASION

ANTI-CORROSION

4

As one of the worlds leading tablet tooling manufacturers I Holland has been instrumental in introducing many innovative and unique developments to the industry including the ‘Rotating Head’, ‘Universal Seal Groove’, and is author of the industry’s leading global tooling standard the Eurostandard.

Since the introduction of PharmaCote® CN in 2007 I Holland has carried out extensive research (both academic and in the field) into anti-stick coating solutions using many forms of advanced technology such as Atomic Force Microscopy (AFM); scanning electron microscopy; laser profilomitry; adhesion mapping; x-ray photoelectron spectroscopy; raman spectroscopy and time of flight secondary-ion mass spectrometry. In addition, work on abrasion resistance is continuing including nano-wear testing to simulate wear caused by abrasive granules on punch tip surfaces.

Our focus is on providing the best customer service possible by furthering tabletting science and developing solutions that help to enhance the performance of our punches and dies, extending product life and increasing yield for our customers. I Holland PharmaCote® products offer solutions for sticking, corrosion, pitting and abrasion.

Due to the many varying parameters in tablet production, including environmental conditions and differences in compounds to be compressed, the performance of these coatings can vary from application to application. As part of I Holland’s commitment to customer service our experienced technical staff will offer up

to date information and assistance when selecting an appropriate PharmaCote® product for your tooling.

This booklet details the range currently available for application to I Holland tooling.The Research and Development team are constantly working on the development of new solutions.

For further information on our R&D activity please contact: [email protected]

Introduction




Example of sticking

5MKT-01 Issue 10

TSAR Project

The aim of ‘Tabletting Science Anti-stick Research’ project (TSAR project), a 24 month programme carried out with the highly respected School of Pharmacy at The University of Nottingham, was to investigate further the root causes of why formulations stick to tablet tooling surfaces. Sticking is one of the biggest problems facing tablet manufacturers today and I Holland lead the way in developing new coatings to combat this issue. Formulation sticking to tablet tooling can be due to several parameters such as: Van der Waals Forces; Capillary Action; Deformation Mechanics and Static Electricity to name but a few. It is these interactions that the TSAR project is designed to quantify, enabling I Holland customers to benefit from a unique ‘optimum coating selector’ drawing on solid scientific research.Using many notoriously sticky excipients and API’s, including Ibuprofen, the TSAR project aims to analyse why one coating prevents sticking

where another does not. I Holland regularly solve these problems through scientific trials but, as this takes time and can increase end user costs, we have chosen to innovate further by developing a predictive tool to speed up this process.




TSAR Project Research Equipment

6

TSAR Project

TSAR uses a variety of highly advanced surface characterisation techniques including: Scanning Electron Microscopy (SEM); Laser Profilomitry; Atomic Force Microscopy (AFM); Adhesion Mapping; X-Ray Photoelectron Spectroscopy (XPS); Raman Spectroscopy and Time of Flight Secondary-Ion Mass Spectrometry (ToF-SIMS - pictured above).

Heading up this high value project is Professor Clive Roberts who has led previous research focussed on quantitative measurements of the surface properties of pharmaceutical materials, using a range of nano-scale techniques, leading to a Queens Award for Industry in 2011. Managing the project for I Holland is Rob Blanchard (Research & Development Manager) with Chris Prideaux (Managing Director) overseeing. TSAR

builds on previous Atomic Force Microscopy research (link) and represents a significant further investment from I Holland which will ultimately benefit customers worldwide.

If you have any queries regarding TSAR or you would like I Holland to apply our Tabletting Science to your project please contact [email protected]




7MKT-01 Issue 10

TSAR≈PREDICT Is A Revolutionary New Service For I Holland Customers

WHAT DOES IT DO?

TSAR≈PREDICT accurately forecasts the correct anti-stick PharmaCote® coating solution for your formulation.

It calculates single particle adhesion to the punch tip face without time consuming and expensive field

trials.

WHO IS IT AIMED AT?

Any tablet manufacturer experiencing sticking problems including pharmaceutical, nutraceutical,

industrial, confectionery, veterinary applications.

WHAT DOES IT COST?

TSAR≈PREDICT is a free of charge service available to all I Holland customers.

WHAT INFORMATION DOES I HOLLAND NEED FROM ME?

All we need from you is the name of the API or main component of the formulation. Even if this API is

confidential we can work with basic characteristic information on key physical properties.

ABOUT TSAR

The TSAR≈PREDICT service is the culmination of two years’ research in association with the University

of Nottingham to investigate the root causes of why formulations stick to tablet tooling surfaces. It

takes into account interactions between various parameters such as Van der Waals Forces; capillary

action and deformation mechanics. This research has been a key part of I Holland’s Tabletting Science

Programme.

T S A R≈

PREDICT

NEW SERVICE


PHARMACOTE® ANTI-STICK

COATING TECHNOLOGY... BACKED BY RESEARCH





THE PHARMACOTE® RANGE




9MKT-01 Issue 10MKT-01 Issue 10

Description A silver coloured coating which protects the surfaces of punches and dies, enhancing corrosion and wear resisting properties and reducing friction and adhesion.

Features Hydrogen de-embrittlement process is carried outThickness: 3-6 micronsHardness: 900Hv (est.)

Benefits Increases surface hardness over base material improving wear resistance Reduces friction and sticking to some extentLow costProvides some general corrosion protectionExtremely easy to clean and maintain using an ultrasonic bath and light automated polishing

Application Can be applied to HPG-S, HPG-P & HPG-SSCan be applied to both punches and dies

PharmaCote® HC (Hard Chromium)




10

Description A unique proprietary I Holland process that modifies the coating surface reducing the effect of formulation sticking to the punch face.

Features Improved anti-stick properties over PharmaCote® HC

Benefits As for HC, PLUS:Increased output through further enhanced anti-stick properties reducing tabletting problems

PharmaCote® HC+ (Hard Chromium Plus)




11MKT-01 Issue 10MKT-01 Issue 10

Description A silver grey coating providing improved anti-stick, anti-corrosion and anti-wear properties over Pharmacote® HC.

Features No micro-cracks (as can be found with Hard Chromium)Thickness: 2-4 micronsHardness: 1700Hv (est.)

Benefits More corrosion resistant than PharmaCote® HC (due to non-porous surface)More wear resistant than PharmaCote® HCWill improve sticking compared to PharmaCote® HC Stronger punch due to no weakening of the substrate material from hydrogen embrittlement. A tougher, shock resistant punch provided at lower cost than premium coatings requiring HPG-P substrate material Extremely easy to clean and maintain using an ultrasonic bath and light automated polishing

Application Applied to HPG-S steel only Applied to punches only (All over coating supplied as standard.)

PharmaCote® EC (E-Chrome)




12

Description A silver grey coating providing a superior punch surface which is very smooth when compared with many CN coatings due to our unique method of application. All round best performing anti-stick coating.

Features Extremely smooth coating Thickness: 2-4 micronsHardness: 2000 Hv (est)

Benefits Excellent anti-stick propertiesSuperb corrosion resistance up to 9X the corrosion resistance of PharmaCote® HCGood wear resistance more than 2X the hardness of PharmaCote® HCExtremely easy to clean and maintain using an ultrasonic bath and light automated polishing

Application Applied to HPG-P & HPG-SS SteelApplied to both punches and dies (NOTE: all over coating supplied as standard, tip & barrel option available to optimise wear characteristics of HPG-P steel on the compression rollers)

PharmaCote® CN (Chromium Nitride)




13MKT-01 Issue 10

PharmaCote® CN+ (Chromium Nitride Plus)

Description An additional surface modification with anti-stick properties at low additional cost. This further reduces the effect of formulation sticking to the punch face.

Advantages Improved anti-stick properties over PharmaCote® CN

Benefits As for CN, PLUS:Further enhanced anti-stick properties reducing tabletting problemsOffers a proven alternative to magnesium stearate spray system without reducing product yieldExtremely easy to clean and maintain using an ultrasonic bath and light automated polishing




14

Description I Holland’s exclusive (Patent Pending) surface treatment in combination with our unique PharmaCote® CN coating generates a superb anti-stick tip face for tablet production.

Features Silver Matt Finish Tip Thickness: 2-4 micronsHardness: 2000 Hv (est)

Benefits Superior anti-stick propertiesGood corrosion resistance Good wear resistance more than 2X the hardness of PharmaCote® HCExtremely easy to clean and maintain using an ultrasonic bath and light automated polishing

Application Applied to HPG-P steel onlyTextured surface treatment applied to punch tip faces only. Remainder of the punch is CN coated as standard (Tip & barrel option available to optimise wear characteristics of HPG-P steel on the compression rollers)

PharmaCote® CT (Textured Chromium Nitride)

NEW!

PATE

NT PEN

DING




15MKT-01 Issue 10

Description An enhanced Chromium Nitride, silver grey coating that is very smooth due to our unique method of application. In addition to all the benefits of PharmaCote® CN, PharmaCote® CX offers prolonged tooling life.

Features Extremely smooth coating Thickness: 6-8 micronsHardness: 2000 Hv (est)

Benefits Prolonged tooling life due to thicker coating applicationExcellent anti-stick propertiesSuperb corrosion resistance up to 13 X the corrosion resistance of PharmaCote® HC Good wear resistance, more than 2 x the hardness of PharmaCote® HC Extremely easy to clean and maintain using an ultrasonic bath and light automated polishing

Application Applied to HPG-P and HPG-SS SteelApplied to punches only (NOTE: all over coating supplied as standard, tip & barrel option available to optimise wear characteristics of HPG-P steel on the compression rollers).

PharmaCote® CX (Chromium Nitride Extra)




16

PharmaCote® CX+ (Chromium Nitride Extra Plus)

Description An additional surface modification with anti-stick properties at low additional cost. This further reduces the effect of formulation sticking to the punch face.

Advantages Improved anti-stick properties over PharmaCote® CX

Benefits As for CX, PLUS:Further enhanced anti-stick properties reducing tabletting problemsOffers a proven alternative to magnesium stearate spray system without reducing product yieldExtremely easy to clean and maintain using an ultrasonic bath and light automated polishing




17MKT-01 Issue 10

Description A thin, gold coloured coating applied to the surfaces of both punches and dies which can improve wear resistance.

Features Low thermal conductivityThickness: 2-3 micronsHardness: 2300 Hv (est.)

Benefits A very hard surface layer that can improve wear resistanceResistance to heat transfer during compression The gold colour can be used for easy identification of tooling setsExtremely easy to clean and maintain using an ultrasonic bath and light automated polishing

Application Applied to HPG-P & HPG-SSSuitable for both punches and diesAll over coating supplied as standard. Tip and barrel option also available

PharmaCote® TN (Titanium Nitride)




18

Description A distinctive silver blue coloured coating applied to the tip of the punch, with superb wear resistant properties but also good resistance to corrosion.

Features Very smooth finishThickness: 2-4 micronsHardness: 3000 Hv (est)

Benefits Our most wear resistant coating due to the very hard surface layerMore than 3 times the hardness of Hard ChromiumExtremely easy to clean and maintain using an ultrasonic bath and light automated polishing

Application Applied to HPG-P & HPG-SSPunch tip only coating - to prevent excessive wear to compression rollers

PharmaCote® RS (Resilient Surface)




19MKT-01 Issue 10

PharmaCote® DN (Dymonic Coating)

Description A black coating which helps to reduce sticking of formulation to punch tip surfaces and improves corrosion and wear resistance.

Features Amorphous structureNon reactive coatingVery smooth surfaceVery hardChemically inertThickness: 2-8 micronsHardness: 1400Hv (est)

Benefits A good non-stick coating for punchesGood resistance to corrosive productsGood resistance to wearEasy to clean and maintain using an ultrasonic bath and light automated polishingBlack colour can help with tooling identification

Application Applied to HPG-S & HPG-SSPunch tip only coating




20

Description A polymer or elastomer insert cut to match the tip shape which reduces sticking of the formulation to the punch face.

Features May be made from a choice of materials (Vulcalon, Adiprene, PTFE)Thickness: 1-2.5mmHardness: variable with material choice

Benefits A good anti-stick solution especially for effervescent productsInserts are replaceable at low cost

Application Suitable for Flat Bevelled Edge and Flat Faced punches only.A modification to the punch tip is required to hold the insert in placeCan be used in conjunction with HPG-S, HPG-P & HPG-SS

PharmaCote® PI (Polymer Inserts)




21MKT-01 Issue 10

Coating Summary

COATINGTooling Type Steel Type

PUNCHES DIES HPG-S HPG-P HPG-SS

PharmaCote® HC (Standard)

PharmaCote® HC (Barrel & Tip)

PharmaCote® HC (All Over)

PharmaCote® HC (Tip Only)

PharmaCote® HC (Head, Neck & barrel)

PharmaCote® HC+ (Standard)

PharmaCote® HC+ (Barrel & Tip)

PharmaCote® HC+ (All Over)

PharmaCote® HC+ (Tip Only)

PharmaCote® EC (Standard)

PharmaCote® CN (Standard)

PharmaCote® CN (Barrel & Tip)

PharmaCote® CN+ (Standard)

PharmaCote® CN+ (Barrel & Tip)

PharmaCote® CX (Standard)

PharmaCote® CX (Barrel & Tip)

PharmaCote® CX+ (Standard)

PharmaCote® CX+ (Barrel & Tip)

NEW PharmaCote® CT (Standard)

NEW PharmaCote® CT (Barrel & Tip)

PharmaCote® TN (Standard)

PharmaCote® TN (Barrel & Tip)

PharmaCote® DN (Tip Only)

PharmaCote® RS (Tip Only)




22

Corrosion Resistance

0

5

10

15

20

25

Corrosion Resistance in hours




23MKT-01 Issue 10

Hardness

0

500

1000

1500

2000

2500

3000

Hardness (Hv)




24

PharmaCote®

Automated Polishing Guide

PharmaCote CN

PharmaCote TN

PharmaCote RS

PharmaCote EC

PharmaCote CX

170018001900200021002200230024002500260027002800290030003100

Hard

ness

(Hv)

PharmaCote® MF Polishing Cycles

PharmaCote HC

PharmaCote DN

PharmaCote EC

600700800900

10001100120013001400150016001700

0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120

Hard

ness

(Hv)

Polishing Cycles (20mins)

Note:

Polishing carried out in I Holland MF35 Compact with Walnut Media and P16 Polishing Paste. Using a different machine or media type will make this data invalid. This data does not take into account wear caused during the compression process.

I Holland R&D Department 27-6-13

The chart above shows the number of automated polishing cycles each coating underwent before initial signs of wear were evident. Please note that manual polishing operations will remove coatings more quickly.

Note: Polishing carried out in I Holland MF35 Compact with Walnut Media and P16 Polishing Paste. Using a different machine or media type will make this data invalid. This data does not take into account wear caused during the compression process.




25MKT-01 Issue 10

MF Automated Polisher

In order to maintain PharmaCote® coatings to an optimum finish, I Holland recommends the use of the MF automated polisher series. The MF polishing range allows you to polish dull and discoloured punches to a micro-fine, high quality finish using a drag finishing process. This range covers varying space and capacity requirements from worktop mountable units to large polishers capable of taking 70 punches per cycle.

MICRO-FINE POLISHING OF TABLET PUNCHES




26

Steels

Refined Steel - ESR

Unrefined Steel

Holland PharmaGrade Powder Metallurgy Steels

There are thousands of steel types available but only a few meet the complex design and functional requirements of tablet tooling. Chemical composition of the steel is only one part of the overall equation, material selection must always be considered alongside good tablet design for strong punch cups and punch tip edges.

To optimise the material and its properties, other processes are required such as:

• Steel refinement (ESR – Electro slag re-melting)• Optimal heat treatment• Treatments and coatings• Powder Metallurgy

All PharmaGrade materials are highly refined to our own specifications and this quality is provided at no additional cost to our customers giving increased strength and wear resistance to tablet tooling.

Steel Refinement - ESRI Holland’s PharmaGrade ESR material (HPG-S & HPG-P) has a homogeneous carbide structure which is distributed evenly throughout the steel. This provides benefits for the end user such as increased tool strength, extended tooling life over conventional (non-refined) steel and coating uniformity.

Powder Metallurgy I Holland offers two specialist powder metallurgy steels (HPG-MP & HPG-MD) each offering a uniform carbide distribution, small carbide size and extremely high wear resistance when compared to HPG-S and HPG-P. Powder Metallurgy steels are recommended for extremely abrasive products.

Holland PharmaGrade Steels HPG-MP & HPG-MD

Holland PharmaGrade HPG-S & HPG-P

Conventional Steel

Cross Sections Showing Carbide Distribution




Durability,

Productivity,

Longevity.

PharmaGrade

MKT-02_Issue_3

This brochure details materials that are currently available for I Holland tooling. The Research and Development Team is constantly working on the development of new materials.

For further information on our R&D activity, please contact [email protected].

27MKT-01 Issue 10




I Holland LimitedMeadow Lane, Long Eaton, Nottingham. NG10 2GD. England

Tel: +44 (0) 115 972 6153 Fax: +44 (0) 115 973 1789Web: www.iholland.co.uk E-Mail: [email protected]

T A B L E T T I N G S C I E N C E




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