Refurbished workhorses

Lars Plüschau

Economical production is quite simply essential to competitiveness in the global market. This often means that production equipment must be appropriately modified. Many of the processes involved in compressing powders and granulates do not necessarily require computer-controlled presses incorporating the highest technology. Frequently, no more than a workhorse is wanted – a machine that will assure continuous production. Moreover, the development and manufacture of dedicated presses for very specific tasks is an expensive matter and therefore likely to prove uneconomical, so that the press models chosen have to be – and remain – in wide use. This is precisely the point where Fette comes onto the stage, with an altogether pragmatic idea that derives from the high quality of the company’s products. Fette tablet presses have a worldwide reputation: the machines are very robust and durable, far better than demanded by warranty periods and specifications. This has the very real effect that, through trade-ins or as a result of direct offers, presses from earlier generations later find their way back to the factory. Since the quality of the machines is still very high, even after many years, they are refurbished and returned to the market.

Conversely, the company’s global presence and close contact with customers often lead to enquiries about reconditioned machines, either for very specific applications or simply as a low-cost alternative. Such enquiries are often accompanied by a need for specific fittings. The machines are overhauled from top to bottom and offered with a twelve-month guarantee. In addition, the full benefits of certified service staff are available for reconditioned machines. The range of machine generations that satisfy today’s requirements is surprisingly large. Four generations are involved: from the P 1000 to P 3000 series, where the first models began work back in 1973, through the P 2100 and P 3100 and on up to machines from all but the last generation, namely the PT 3090, P 3200, PT 2090, P 2200 and P 1200 built between 1991 and 2007. Single and double-sided rotary presses are found in all of these generations. The maximum output from the presses reaches from 183,000 to 1,004,880 tablets/h, in other words they cover a broad spectrum. They are accordingly suited for many applications, depending on the kind of performance expected of the press.

The reason why reconditioned machines from the generation immediately preceding the current one are already available is the heavy usage to which they are often put. In some cases, the presses run for 24 hours a day and are only switched off for scheduled servicing, product changes or cleaning. This results in a relatively short payback period and the early achievement of profitable operation – thanks not least to the easily calculable lifetime costs. Fette works closely with every well-known pharmaceutical manufacturer in the world, including the makers of branded products that are consumed everywhere – in corresponding quantities. This inevitably implies that the presses are put to intensive use, which in turn shortens the time until the machine stock is upgraded. In the pharmaceutical industry, these machines are in particularly heavy demand from the manufacturers of generic products and from countries outside Europe, where their high technical standard is held in high esteem in combination with the comparatively low price. Nevertheless, there is a also strong demand for older press generations, some of which are not computer-controlled and have only limited automatic functions or even a few operating phases that have to be manually controlled.

Since the central task of a press simply comprises the compression of powders and granulates, it is perfectly acceptable for a press that was originally employed for tablet production in the pharmaceutical industry to be refurbished and then used in a to-tally different industrial sector. The same press could, for instance, at some time in the future be installed in a confectionery plant for making sweets or in a pet food factory that puts together nourishing meals for domestic animals. In the chemical industry, the potential applications could include the production of washing and cleaning agents or the compression of powders to form catalytic elements, while in the electrical industry, battery cores might be manufactured.

Reconditioned presses are a viable alternative wherever compression is required. It should be borne in mind that there are many special types of product for which dedicated presses either do not exist or where customised development would not be economical. The proven robustness of these machines is an important factor in this equation. The production of small to medium-sized batches is an extremely wide field for the use of older press generations.

The presses are completely dismantled at the maker’s factory; the individual components are carefully examined and checked for proper performance in their mechanical interaction with other parts. This affects all stationary and moving equipment or functions. Any defective or worn parts are exchanged for OEM replacements. The electric drive and the remainder of the electrical equipment are treated with the same thoroughness. The function of all control elements is tested and special attention paid to their future availability, while any software that may be installed is updated. The manufacturer is consequently able to give the buyer a full twelve-month guarantee on all parts and functions. The refurbishment also includes renewal. All innovations that have been developed over the years for the type of machine concerned are incorporated. The press therefore complies with the state of the art for its particular series and can also include equipment that the company offers as new in the framework of ongoing product maintenance. As a rule, however, potential buyers who enquire about a specific type of press have their own idea of how this press should be fitted out. This begins with the tools which, of course, can also be manufactured and supplied by Fette. On top of this, turrets with various numbers of stations can be freely selected for any machine version. All turrets are entirely new parts.

This complete renewal of the machines includes standard documentation. The manufacturer moreover offers a calibration certificate for the majority of models as well as an internal acceptance certificate for the press. There are thus no obstacles to using the press for strictly controlled applications, such as in pharmaceutical production. As mentioned briefly above, a full, worldwide guarantee service – provided by maintenance engineers with dual training – is available to customers. This applies not only to commissioning and qualification support but also to inspection, servicing, repairs and training for operating personnel. Finally, the manufacturer can assure comprehensive availability of spare parts for all three generations of presses. This Fette concept, combined with the services described here, represents an eco-nomical alternative for any sector of industry.

Hall 3.0, Booth H5

Online-Info www.cpp-net.com/2209459