by N. S.
SOLIDA and DOMINA tablet presses represent two benchmarks for those seeking a precise, reliable, and fully automated compression process.
SOLIDA is designed to ensure precision, process stability, and ease of setup even during development phases. DOMINA is designed for high-speed production and integrates in-line monitoring systems that ensure uniformity and reduce waste even in the most intensive cycles. The complete intelligent automation that characterizes both solutions from IMA Active improves repeatability, limits operator-dependent errors, and guarantees production continuity, elements that are essential today.
“SOLIDA and DOMINA support the operator at every moment,” says Andrea Semprini, Vice President of IMA Active. “The interfaces guide the operator step by step, making it easy even to set recipes and to control the most important parameters. And then there are the adaptive systems, which automatically regulate the working conditions to keep the quality of the finished product stable. Among the new features of the new machines,” he continues, “I would like to highlight the Dynamicam. This IMA Active patented filling cam makes it possible to customize production with automatic adjustments directly from the HMI: no manual or mechanical interventions are needed. This reduces format changeover and set-up times and increases system safety.
SOLIDA and DOMINA are designed for the Pharma 4.0 industry: a technology that supports people and that can also learn. Design and Made in Italy can be seen in the attention to detail and in reliability. They are innovative machines, designed to ensure high performance, production continuity, and a return on investment that the pharmaceutical market has always appreciated.”
How IMA Active addresses the global challenge
“The tablet press market is a highly competitive global market, but still with many growth opportunities,” explains Luca Cavazzini, Sales & Marketing Director of IMA Active. “Just think about oral solid dosage forms: tablets account for about 80% of the total. It is a figure that explains well how strategic it is to be strong in this sector, and this is why the company invested in SOLIDA and DOMINA.” Cavazzini continues with a broader view. “International scenarios change rapidly. About four years ago we acquired the Chicago plant dedicated to tablet coating: a local presence allows us to reduce response times, facilitate service and validations, and better adapt supplies to the requirements of the American market.”
Homogeneous technology for different markets
Adapting to the requirements of the various international markets means focusing on higher packaging standards, valid everywhere. The sector is moving towards stricter rules, both on the production process and on packaging materials, which will have to be increasingly sustainable.
Luca Cavazzini states: “The large multinationals we work with have plants in the United States, in Africa, in the Middle East, and in South-East Asia. Our technologies must work smoothly at each of these sites. Our positioning remains high: in the lower tiers competition is almost only on price, and this would risk reducing the value of our equipment. For us, research and development is a strategic lever, and we continue to invest in it significantly to offer solutions that are valid everywhere, even in markets where price sensitivity is higher.”
Cavazzini continues: “To serve the more ‘price sensitive’ markets we use different tools. Our plants in China and in India were created precisely with this goal: to be closer to customers, manage overall costs better, and remain competitive without giving up the technological level of our machines.”
Plant modularity: decisive for markets, products, and batches that are so dynamic
“Why choose a modular plant?” Luca Cavazzini begins. “For us it is one of the most strategic characteristics of our machines. Today markets change quickly, products are updated continuously, and batches become increasingly variable. To keep up, a flexible, modular line is needed, capable of adapting to the needs of the moment. Companies must move from one format to another very quickly, and a modular line gives the peace of mind to invest, knowing that the plant can be reconfigured without invasive interventions. For this reason we design IMA machines already ready for multiple configurations and easily upgradable. It is an approach that makes it possible to offer technologically advanced solutions both to large multinationals and to medium-sized companies.”
“Modularity,” Cavazzini adds, “makes it possible to manage an enormous variety of products, formats, and specifications. And this also reduces the time to market of oral solid dosage forms, an aspect that today really makes the difference. In addition, there is an important topic: sustainability. On the one hand, there is no need to replace the machine, because it is enough to add modules and functional units to reconfigure production, extending the useful life of the investment. On the other hand, waste of resources and materials is avoided: what already exists is reused instead of scrapping an entire plant,” and he concludes: “and let us not forget the digital twin. They enhance the value of modularity because they make it possible to simulate different configurations, formats, and layouts, to understand the impact on production flows even before starting real production. This helps to make more informed decisions, reduces errors, and shortens start-up phases. A concrete help for those who work every day in industrial production.”
Pharmaceutical, nutraceutical, and detergents: opportunities are growing for tablet presses
“The tablet market, which for years was almost exclusively pharmaceutical, is now opening up to new sectors,” explains Luca Cavazzini. “Nutraceuticals, in particular, are growing very quickly and now represent a truly important share. This leads to an increase in demand for tablet presses capable of ensuring high productivity and consistent quality of the finished product. Our tablet presses are born with pharmaceutical DNA: high standards, advanced functionalities, precise process control, and stable quality. Nutraceuticals are getting very close to these requirements, and the gap compared to pharmaceuticals is now minimal. For this reason, our machines work smoothly in both fields, and nutraceuticals have become a strategic area for us. In addition to pharmaceuticals and nutraceuticals, there is also the market for detergent tablets. It is an important sector, with its own characteristics: different formulations, raw materials that can be abrasive, and a very strong focus on productivity and cost per unit. Thanks to the experience gained on pharmaceutical machines, we can offer robust and reliable solutions also in this field, fully in line with what the detergent tablet market requires”.
Finally, he concludes: “The main difference between pharmaceuticals and nutraceuticals is often economic. Nutraceutical companies are more price-sensitive, but at the same time they require high performance, reliability, and quality. The technologies developed for pharmaceuticals respond perfectly to these needs. A tablet press built to pharmaceutical standards operates without difficulty in nutraceuticals and even in other tablet markets, such as detergents. In this way, it offers flexibility and an excellent return on investment.”
From NEXTEN come SOLIDA and DOMINA
At the end of October, during NEXTEN on Lake Como, IMA presented the innovative tablet presses: SOLIDA and DOMINA.
- SOLIDA ensures high productivity, rigorous process control, and stable quality of the finished product.
- DOMINA prioritizes maximum flexibility, fast format changeovers, and intuitive interfaces for the operator.
The two platforms represent IMA’s new offering for powder compression: operational efficiency, product safety, and reduced line downtime.
SOLIDA, the intelligent tablet press with great performance
The SOLIDA tablet press integrates easily into existing production lines, is simple to start up, and is ready for possible upgrades. The operator has an intuitive machine, quick in adjustments, equipped with technical solutions that keep the quality of powder compression constant. The robustness of this tablet press is suited to a wide range of production volumes. SOLIDA is able to support the growth of pharmaceutical and nutraceutical departments over time.
There are several strengths:
- Isolation of the process area: complete separation between the process area and the mechanical area thanks to dedicated seals and protections. The surfaces in contact with the product are minimized, so cleaning times are shortened and the risk of contamination decreases.
- Fast turret changeover: the integrated rotating arm makes it possible to complete the operation in a few minutes, following a clear procedure guided by the HMI. This reduces the risk of errors and makes every intervention safer.
- Faster cleaning: the process area is fully accessible with the doors open; the base frame is reached only for maintenance operations.
- MAX is SOLIDA’s HMI: an operational control tool with a fast learning curve. Prepared with KORTEX on board, a SCADA based on iFix, ready for IoT and easy to integrate with higher levels (MES/ERP) both within the plant and across different sites. It simplifies press control, supports format changeover and maintenance, and helps reduce errors and downtime.
From automatic lubrication to quality control for defect-free tablets
The lubrication system integrated into the machine base works automatically on the pre-compression and compression rollers, together with the punches and cams. The oil does not enter the process area and lubricant consumption is optimized, the machine remains clean and the frequency of maintenance interventions is reduced.
To support high loads and reduce the risk of defects on tablets, SOLIDA is based on an extremely robust structure. The upper and lower cast-iron sections are rigidly connected and make it possible to handle pre-compression and main compression forces up to 100 kN. This rigidity translates into process stability even at the highest speeds.
A key element for the production of defect-free tablets is in-line quality control. SOLIDA enables the rejection and sampling of single tablets both in single-layer configuration and in double-layer (bilayer) configuration. This control, integrated into the production flow, helps to constantly monitor the process, intervene in the event of deviations, and ensure that each batch meets the quality standards required by the pharmaceutical and nutraceutical industry.
Quality tablets with DOMINA’s modularity
The DOMINA tablet press is a modular platform with functional blocks that are easily removable and interchangeable. Its architecture allows an almost immediate switch between different configurations, without complex modifications and with reduced downtime. It can be set up according to the product to be processed, adapting flexibly to different powder formulations and to different tablet shapes and requirements.
Compared to traditional tablet presses, DOMINA introduces a higher level of automation and flexibility to assist the operator in adjustments, maximizing production and reducing errors. The interface is simple to make settings and routine operations fast.
Thanks to its modularity, the tablet press can quickly adapt to new production needs, following market evolution. It is a machine that covers multiple process configurations, guaranteeing reliability and high performance in all applications where precise, repeatable, and controlled compression is required.
DOMINA can be equipped with Preforma. We are talking about a special compaction cam that improves powder deaeration. This solution significantly reduces the risk of lamination and capping, i.e., the detachment of the tablet “cap”, two typical defects in more complex formulations. The fast reconfiguration from single-layer tablet production to bilayer production further expands the field of use.
Advanced diagnostics, Dynamicam, and KORTEX MAX for safe and continuous compression processes
The tablet press is designed to operate in the most advanced production environments of the pharmaceutical industry. Its advanced diagnostics allow the machine to adapt to the context, learn from the process, and suggest improvements, offering concrete support to the operator.
DOMINA automates the upper and lower pre-compression and compression axes, with adjustments from the HMI: process control is simpler and working conditions are more repeatable from batch to batch. Punch clamping and the dedicated load cells are equipped with real-time adaptive diagnostics functions, which stabilizes the process and increases its repeatability. The patented Dynamicam filling cam covers the entire filling range and, combined with independent motorization of the paddles, allows fine tuning centered on the product, effective even with sensitive powders or powders that are difficult to compress.
DOMINA’s advanced intelligence has direct effects on quality, scrap, and start-up times. Optimized start-up, stop, and set-up procedures reduce scrap close to zero and shorten the ramp-up phase, improving line availability and overall plant performance. The press integrates KORTEX MAX, which combines HMI and supervision. The automation system ensures an immediate response to commands, predictable behavior, and a short learning curve for the operator.
DOMINA was designed from the beginning to meet the requirements of Pharma 4.0. It protects data integrity, integrates cybersecurity functions, is ready for IoT and for advanced analysis of process data, and is set up for Continuous Manufacturing. DOMINA can communicate with the most modern factory systems and support the digital evolution of pharmaceutical plants over time.
DOMINA’s strengths:
- Fast turret changeover and fast cleaning: integrated rotating arm, servo-assisted operations guided by the HMI.
- Fully accessible process area: reduced product-contact surfaces for fast cleaning; the machine base is accessible only for maintenance, for minimal downtime and higher daily availability.
- Compactness and efficiency: limited footprint for in-line integration; anti-vibration and sound-absorbing solutions; brushless motors for reduced consumption.
- Robust structure and performance: PREXIMA-derived architecture, rigidly connected upper/lower cast-iron frames; pre-compression and main compression up to 100 kN; rollers all with the same diameter and double supports to achieve uniform force even at high speeds.
- Productivity and quality: IMA 8 tooling and segmented technology for high output (tablets up to 11 mm); automatic lubrication with recirculation.
- In-line control: rejection and sampling of single tablets, single-layer and double-layer (bilayer), to continuously monitor quality and immediately detect deviations.
In addition, DOMINA integrates functions for quality control, for rejection and sampling of single tablets, both in single-layer configuration and in double-layer (bilayer) configuration. This in-line control allows continuous monitoring of process characteristics, detecting any deviations before they become anomalies in the batch, keeping tablet production defect-free.
