The PG40 high-speed rotary tablet press must strictly follow the standardized procedure of "pre-check confirmation → no-load trial run → parameter matching and debugging → formal production." Before operation, the equipment must be confirmed to be in good condition, and operators must hold special equipment operation certificates to ensure production safety and tablet quality from the source.
I. Static Pre-Check Before Startup
(I) Critical Components and Environment Inspection
1. Inspect the 40 sets of punch and die assemblies, pressure rollers, powder scrapers, and feeding hoppers to ensure they are intact, free from damage or jamming. The punch and die specifications must precisely match the production formula; the punch rod diameter and die hole size must fully adapt to the material characteristics. Hansheng Automation can perform single-piece or small-batch precision machining according to customer-provided design drawings, using high-quality die steel with tolerances controlled within ±0.01 mm, and providing surface hardening or coating treatments to effectively solve problems of non-standard punches and dies being prone to wear and poor adaptability.
2. Check that the oil levels at lubrication points such as the main shaft bearings, guide rails, and cam mechanisms are normal, and that the lubricant grade strictly complies with the equipment manufacturer's original manual requirements.
3. Thoroughly clean residual materials and debris from the hopper, feeding track, and collection area to ensure the material conveying channel is unobstructed.
4. Confirm that the electrical cabinet door is closed, and that the emergency stop button and safety door interlock devices function normally; after pressing the emergency stop button, the equipment main circuit must be immediately cut off.
(II) Material and Document Verification
1. Verify the material formula and batch information for this production run, and prepare the corresponding production materials.
2. Confirm that production records and quality standard documents are complete and fully comply with GMP production requirements.
II. No-Load Trial Run
1. Close the main power switch, start the dust extraction fan and hydraulic system (if equipped), and confirm that the auxiliary systems have no abnormal noise or leakage.
2. Disconnect the main motor power, manually turn the machine 2-3 revolutions, and check that rotating parts have no jamming or collision and that all mechanisms have good synchronization.
3. Close all safety doors, restore the main motor power, switch the equipment mode to no-load debugging, start the main motor, and run at 30% of the rated speed for 5-10 minutes, observing for no abnormal vibration or noise.
4. Gradually increase the speed to 60% of the rated speed and continue running for 15 minutes; check that all sealing parts have no powder leakage, lubrication points have no oil leakage, and pressure displays are normal.
5. After the no-load run, press the emergency stop button, cut off the main power, and check the temperature of each rotating part; the temperature of the main shaft and pressure roller bearings must not exceed the ambient temperature +40°C.
III. Material Trial and Parameter Matching
1. Set the core parameters according to the production formula: main motor speed, filling depth, tablet compression pressure (set via the pressure roller adjustment mechanism and flexibly adjusted according to material hardness requirements), and feeding speed.
2. Load a small amount of blank material of the same formula or talcum powder as trial material, start the equipment at low speed, observe tablet forming conditions, and adjust the filling amount and pressure roller pressure until tablet weight variation and appearance meet quality standards.
3. Continuously run for 30 minutes, confirm there are no issues such as punch sticking, tablet cracking, loose tablets, or sticking, sample and test tablet weight, hardness, and friability; after all are qualified, proceed to the formal production stage.
IV. Formal Startup and Production
1. Add the production material into the feeding hopper and adjust the feeding device speed to ensure a uniform and stable material layer.
2. Switch the equipment mode to automatic production and gradually increase the speed to the rated production speed.
3. Continuously monitor the equipment operating status and record key parameters such as tablet weight, pressure roller pressure, and speed every 15 minutes.
4. If abnormal noise, punch sticking, powder leakage, or other problems occur, immediately press the emergency stop button to stop and investigate; never continue running with hidden risks. We possess drawing-based customization capability and can quickly respond to specialized parts for packaging machinery, providing customers with precision machining support for critical components such as pressure rollers and punches/dies to ensure long-term stable equipment operation.
