OBJECTIVE
To lay down the procedure for the operation and cleaning of Compression Machines.

SCOPE
The procedure applies to assembling, operating and cleaning the compression machine

RESPONSIBILITY
Operator: Shall be responsible for operating and cleaning of equipment.
Supervisor: Ensuring that procedure is appropriately followed for optimum output and longer machine life span.

PROCEDURE

Operation of Machine
  • Check the lubrication of the machine after every changeover.
  • After cleaning, if the machine is not utilized within 24 hrs. clean the machine with lint free duster before use.
  • At the end of the day, remove the upper punches and put it again after cleaning them with dusters.
  • Record and sign the destruction details in respective product BMR.
  • Wear a nose mask & hand gloves.


  • Rotations of the machine should be in a clockwise direction.
  • Check punches are free in punch guides.
  • Check punch's body is lightly smeared with oil.
  • Check feed frame is properly assembled.
  • Update the status board with details.
  • Keep the machine OFF. & engage the clutch by pulling out the clutch lever.
  • Keep the machine ON and rotate the machine by jog and complete the rotation of the turret to ensure proper setting of dies and punches.
  • Load the blend in the hopper, if necessary adjust the height of the hopper.
  • Keep the polythene-lined container below the chute.
  • Rotate the machine by jog and increasing the sufficient pressure to form tablets
  • Rotate the machine by jog and complete the rotation of the turret to ensure free rotation
  • Disengage the clutch.
  • Switch ‘ON’ the mains.
  • Switch ‘ON’ the machine.
  • Operate the clutch.
  • Collect the sample tablets of one rotation & check the specifications as per the respective product BMR.
  • Check the parameters of tablets as per the respective product batch manufacturing records.
  • If necessary, adjust the parameters by setting the machine as per respective product BMR.
  • Compress the batch as per standard parameters specified in the respective product BMR.
  • Check the parameters are within limits, as per the frequency given in BMR.
  • After completion of compression stop the machine by disengaging the clutch.
  • After completion switch off the machine by pushing the OFF switch.
  • Switch off the mains.
  • Make the machine dust-free by a vacuum cleaner.
  • Update the status board with details.
  • Release compression pressure.


Cleaning of Machine

Cleaning for product-to-product change over
  • Update the status board with details.
  • Release the pressure of the lower punch by rotating the pressure wheel spring anti-Clockwise.
  • Remove powder from a turret, upper punches, lower punches & machine by a vacuum Cleaner.
  • Remove the hopper, upper punch locking plate per punches & feed frame by unscrewing the screws.
  • Remove side guards by unscrewing the screws.
  • Clean the upper punches with diesel and duster.
  • Apply oil on the tip and body & store in the punch box.
  • Unscrew the lower punch anti-turning device.
  • Remove the lower punch window lock.
  • Remove lower punches. Clean the lower punches with diesel and duster.
  • Apply oil on the tip and body of the lower punches & store in the punch box.
  • Unscrew the die-locking screw. Remove the dies with the help of Tommy.
  • Clean the dies & keep them in a punch box.
  • Clean the body of the machine from top to bottom with diesel and duster.
  • Clean the die, apply oil to the screws & punch guides with diesel & duster.
  • Remove the feed frame stand by unscrewing the screws.
  • Wash the feed frame stand, feed frames & hopper with water till visually it is cleaned.
  • Wash the feed frame stand, feed frames & hopper with 1% soap solution.
  • Wash the feed frame stand, feed frames & hopper with water till the detergent is removed.
  • Rinse the feed frame stand, feed frames & hopper with purified water.
  • Send rinse sample for QC analysis.
  • Keep the cleaned parts on a clean SS trolley. Allow them to dry.
  • Take out the punch box & store in punch storage racks.
  • If the machine is not used after cleaning within 24 hours, the Machine to be re-cleaned by following the procedure above.

Cleaning for batch-to-batch changeover
  • Frequency of cleaning to be done after every 3 batches
  • Clean the machine as per the above steps.


Setting of the machine for round punches
  • Take the required punch set. Clean the dies with dusters from inside & outside.
  • Ensure the cleanliness of machines change parts, machine, and de-dusting units & filter bags.
  • Fix the dies in die cavities with the help of Tommy. Fix the dies by tightening the die-locking screw.
  • Clean the lower punches with a clean cloth and smear the body of the punches with oil.
  • Remove the oil from the tip.


  • Put the lower punches through the punch-loading plug.
  • After putting all lower punches close the lower punch-loading hole by window lock.
  • Tighten the punch anti-rotating pins to prevent the rotating of punches.
  • Tighten the lower punches so tight that punches should move up & down after pressing only.
  • Smear the oil to the body of the upper punches. Put the upper punches.
  • Rotate the turret by hand wheel & check for setting.
  • Fix the lower cam guards. Fix the feed frame stands & feed frames.
  • Fix the hopper.
  • Update the status with details.


Setting of the machine for shaped punches
  • Take the required punch set. Clean the dies with dusters from inside & outside.
  • Remove the upper punch cam plate. Place upper punches smeared with oil to the body & place the die with punch tip in the die cavity.
  • Fix the die by hammering gently along with an upper punch and tightening the die-locking nut.
  • Check the free movement of the upper punch & fix other punches in the same manner.
  • Fix the upper punch cam plate. Rotate the machine by hand and & check the settings.
  • Fix the removed piece on the upper punch cam plate.
  • Fix the dies in die cavities with the help of Tommy. Fix the dies by tightening the die-locking screw.
  • Clean the lower punches with a clean cloth and smear the oil on the body of the punches.
  • Remove the oil from the tip.
  • Put the lower punches through the punch-loading plug.
  • After putting all lower punches close the lower punch-loading hole by plug.
  • Tighten the punch anti-rotating pins to prevent the rotating of punches.
  • Tight the lower punches so tight that punches should move up & down after pressing only.
  • Put the upper punches. Rotate the turret by hand wheel & check for setting.
  • Fix the lower cam guards.
  • Fix the feed frame stands & feed frames.
  • Set the scraper blade & ejector plate & ejection level. Fix the hopper.
  • Update the status with details.

ABBREVIATIONS
SOP: Standard operating procedure
BMR: Batch Manufacturing Record.
SS: Stainless steel.

REFERENCES
Equipment manual

REVISION HISTORY
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