The New KORSCH X 3 Tablet Press
Maximizing Mid-Range Production
The X 3 is a breakthrough in the small-scale and mid-range tablet press market segment, designed from the ground up to incorporate the latest KORSCH advancements. The X 3 is a single-sided rotary tablet press that redefines flexible technology with a new approach to architectural and ergonomic design elements, which were previously available only on larger machines. The X 3 is smarter and Pharma 4.0 ready, which permits a deeper understanding of what is happening in the compression suite. This is the basis to optimize both the process and the manner in which the process is executed by the operations team to obtain maximum product quality.
X 3 TECHNICAL WEBINARS
KORSCH offers technical webinars to present the new X 3 Tablet Press. Experts from our Innovation Center in Berlin will provide a live demonstration and full presentation on the technical innovations and advantages of the X 3 technology.
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The X 3 is a robust, portable, single and bi-layer rotary press which is ideal for scale-up, clinical manufacturing and mid-range production. The integrated control cabinet avoids additional space and cabling in the room. The single and bi-layer capability, and exchangeable turret technology offer unprecedented flexibility that permits the press to be adapted to future production requirements. The innovative, self-contained design of the X 3 offers a range of installation options such as portable platform, conventional installation in compression suite, through-the-wall installation. The X 3 offers a range of product containment configurations, including OEB 3, as well as OEB 4/5 with full wash-in-place and high-containment execution.
The X 3 features large windows for excellent visibility and unlimited access to the compression zone to streamline product changeover and turret exchange. At the rear of the machine, the Multi-Function Column houses in two separate compartments, the electrical components and the main dust extraction connection. The water-cooled chiller serves both the torque drive as well as the heat exchanger in the integrated electrical cabinet. The result is a fully sealed machine with no heat transfer to the compression zone of the press, or to the compression room. The closed design ensures no contamination in the machine base or electrical cabinet to support the streamlined cleaning and changeover.
The X 3 is fully prepared to fit into the smart factory concept. The KORSCH control system features an open architecture and the ability to easily integrate the machine to a central network, with domain authentication, central recipe management, and central batch report archiving. In addition, a standard OPC server permits press parameters to be passed to a SCADA or Historian system in real time. Advanced capabilities further leverage the data through secure cloud solutions for OEE assessment and predictive maintenance. In addition, machine data may be made available for sharing with the outside world. This digitalization strategy for the machine design will provide a higher product quality, lower total cost of ownership, and significant advantages and convenience in the day-to-day machine operations, from electronic production monitoring to operator assistance through virtual reality.
KORSCH Introduces Next-Generation Mid-Range Tablet Press
X 3 Tablet Press incorporates production capabilities and versatility traditionally limited to large-scale production machines
State-of-the-art-tableting technology meets the midrange segment at last. The days of having to compromise are over. KORSCH is introducing a groundbreaking mid-range tablet press incorporat-ing innovative features previously available only on large production machines. The new X 3 Tablet Press is a single-sided rotary press that redefines this market segment, with flexible technology and a new approach to architectural and ergonomic design.
Suitable for product development, scale-up, clinical production, mid-range production and continu-ous manufacturing, the next-generation X 3 Tablet Press is available in two models. The X 3 SFP is a dedicated single-layer press capable of 266.400 tablets/hour, while the X 3 MFP offers flexible single-layer (266.400/hour) and bi-layer (133.200 /hour) production capability.
Among other innovations, the X 3 incorporates a flexible manufacturing experience atypical for its size, with an integrated electrical cabinet, torque drive, fully sealed design, and unsurpassed acces-sibility for cleaning, changeovers and maintenance. Installation options include a conventional in-room layout, through-the-wall mounting, and a portable equipment platform. The X 3 offers a range of product containment configurations, including OEB 3, as well as OEB 4/5 with full wash-in-place and high-containment execution.
X 3 maximizes flexibility, efficiency and output
Of note, the X 3’s exchangeable turret technology allows for an extremely fast transition between products, and the ability to produce a tablet of any size and shape. A mixed turret, with B and D punch bores, permits the ability to conduct product development with reduced tools and to change tooling formats without requiring a turret exchange. The X 3 can be fully instrumented for the measurement of precompression, main compression and ejection forces; for even more detailed analysis, an optional, integrated data acquisition system offers full characterization of the force-time waveform, and documentation of scale-up parameters.
For mid-range manufacturing, the X 3 offers a long filling length and large, variable-speed power feeder for precision die filling at extremely high speeds. For changeovers, superior compression zone access, smooth surfaces, and minimal fast change parts yield an expedited process for max-imized machine uptime. This combination of high-speed and fast-change translate to unprecedent-ed efficiency for the mid-range market segment.
The unique KORSCH machine structure allowing the elimination of corner columns, combined with large windows, provide excellent visibility and unlimited access to the compression zone for stream-lined changeover and turret exchange. At the rear of the machine, a multi-function column with two separate compartments houses the electrical components and the main dust extraction connection, while the water-cooled chiller serves both the torque drive and heat exchanger. The result is a fully sealed machine with no heat transfer to the compression zone of the press, or to the compression room. This closed design also eliminates potential contamination in the machine base or electrical cabinet, and further expedites the changeover process.
The X 3 also minimizes both noise and vibration. A carrier plate supporting the dual column for pre- and main compression is mounted on pneumatic dampers – a patented design that fully isolates vibration from the head piece and machine base. The result is significantly reduced operating noise (< 80 dB) and elimination of vibration transmission. The dual compression column is fixed on the carrier plate and features a swiveling lower compression roller design to facilitate expedited clean-ing and turret exchange.
Fit for a Pharma 4.0 future
The machine control system is based on Siemens SIMOTION using a smart-touch HMI with exten-sive onboard operation and maintenance assistance, delivering an intuitive operator experience. The operator gains access to all process data and documentation as well as to comprehensive help documents during ongoing operation. KORSCH PharmaView®, a holographic operational assistant, based on Microsoft HoloLens augmented reality technology, can also be used on the X 3. The Augmented Reality glasses beam holograms and additional information into the user’s actual visual axis, enabling guided, hands-free setup, operation and maintenance support. The remote service via video call permits secure, streamlined troubleshooting that saves time, reduces costs, and im-proves overall efficiency.
KORSCH tablet presses are designed to dovetail with the smart factory concept and the X 3 is no exception. Smart sensor technology with an IO-Link for data pre-processing enables a new level of centralized data collecting process and of machine parameters storage. Electronic type plates also log the type, configuration and calibration of each component. All data can be transferred via a pro-prietary secure cloud solution or KORSCH-PharmaInsights®. A sophisticated analysis of perfor-mance indicators can then help to localize immediate (OEE) optimization potential, to increase ma-chine availability and output, to reduce energy consumption and to coordinate maintenance inter-vals better. Central formulation management, batch report archiving, and predictive maintenance functions are just initial examples of the smart use of data to ensure that production is always effi-cient and transparent and to keep total operating costs low.
Official market launch in September
Potential buyers can find out everything about the tablet press innovation of the year at www.maximizing-mid-range.com. The X 3 is also available for demonstration at the KORSCH INNOVATION CENTER in Berlin following its official market launch in September.
About KORSCH AG
KORSCH AG, based in Berlin, is the tablet compression specialist and go-to partner for the entire manufacturing process. The family-run, mid-sized machinery manufacturer, which employs ap-proximately300 people, has been harnessing its cross-industry skills for 100 years to create both standard and special solutions for a wide variety of markets, including pharmaceutical, confection-ary, chemical, and technical industries. Its innovative and highly flexible machinery systems offer state-of-the-art technology for feasibility, development scale-up, mid-range, and high-speed produc-tion. Alongside its key overseas branch in the USA, KORSCH America Inc., the company has also been represented in India by a subsidiary in the city of Mumbai since 2016 and has a global sales and service network at its disposal to guarantee a seamless service. Furthermore, the state-of-the-technology-art KORSCH INNOVATION CENTER in Berlin provides the perfect learning and work-ing environment for product development and the optimization of all tableting processes. For more information, visit www.korsch.com.
Phone: +49 30-43576 373