It is almost impossible for the naked eye to detect microscopic signs of abrasive wear and corrosion, which can reduce the effectiveness of a pharmaceutical tablet application. The high-performance equipment used by pharmaceutical companies in the manufacture of tablets and capsules requires highly polished, scratch-free surfaces to maintain the surface contact needed to compress powders and develop a stable, high-quality product. Unfortunately, standard steel tools, such as the D-series, S-series and stainless steel (408, 440C), are attributed to abrasive wear and corrosion. Since the working surfaces of the punches and die from wear and corrosion, there are a number of physical phenomena that affect the performance of the tablet and increase production costs.
Increased mechanical interlock -
When microscopic scratches and pits appear on the surface of the instrument, pharmaceutical powders can become trapped in these surface defects. As the additional tablets are compressed, the powders will adhere to particles trapped on the surface and begin to accumulate on the surface. Unfortunately, due to the fact that these flaws are almost invisible to the human eye, the effects of these scratches and pits are not noticed until it is too late. Occasionally sticking and collecting occur, and production must be stopped to remove and clean the punches. Losses for the manufacturer are quickly mounted every second when production is disabled.
Similarly, if corrosion-corrosive layers and rust surfaces form on the surface of the punch, the powders will adhere to the rough rust layers. Cleaning with detergents or solvents will remove glued powders, but will not restore the original finish of the instrument's surfaces. The tool in this state requires regular polishing and polishing to smooth out scratches and pits and remove corrosion products in order to return surfaces to working conditions. Again, production must be stopped to remove and polish the machines.
Increased friction between powders and perforated surfaces -
Due to scratches or corrosion, rough surfaces will also increase frictional forces, since the formulary powders flow along the edges of the punch during compression. Since the production of pharmaceutical tablets is an extremely accurate process, the slightest flaws in the process at any level will lead to an increase in the number of additional problems on the line. Manufacturers use predetermined levels of materials that have been found to achieve the highest levels of efficiency. After minor surface abrasions begin to appear in the instrument, predetermined levels of lubricants and sliding particles will no longer be effective. Higher compression forces may be required, and the work of ejection will increase.
Reduce the life of tablet compression tools -
The permanent restoration of worn and corroded perforated surfaces by polishing and polishing has a significant negative impact on tool life. Buffer compounds contain abrasives that actually remove thin layers of the metal surface to polish scratches and pits. Re-polishing can reduce the critical dimensions of the punch in the area of the earth at the tip of the punch, thereby reducing the fit between the punch and the punch. Constant polishing also leads to a rapid deterioration in the proportions of the relief signs on the punches. In both cases, the useful life of the strike is significantly reduced.
Instead of continuing the cycle of abrasive wear, restoration and subsequent further degradation, pharmaceutical manufacturers have additional opportunities to maintain the surface integrity of high-performance tooling. There are a number of different maintenance coatings, each with different advantages and disadvantages. Some precision metal coatings, such as those used with the IBED coating method, are capable of protecting and improving the surfaces of the tool for compressing compression materials and applying them at low temperature, which eliminates the possibility of dynamic tool distortion. The result is a longer service life and increased efficiency in the use of pharmaceutical compression.
