by N.S.
This in-depth article focuses on SOLIDA; IMA Active’s tablet press designed for the pharmaceutical industry and ideally suited to the nutraceutical sector. It stands out as a “universal” choice, combining robustness and ease of use across different production environments. It enables fast start-ups when product codes are numerous and batch changeovers are frequent. At the same time, it supports continuous production without adding complexity to operators’ daily activities.
The global nutraceutical challenge starts from the pharmaceutical
In nutraceuticals, the required standards are becoming increasingly close to those of the pharmaceutical sector. Volumes are growing, and many companies are choosing to standardize plants and procedures by using the same production platform for different markets, reducing errors and shortening the time needed to launch new products.
Attention is focused on the technological aspects: fast format changeovers to manage smaller and more frequent batches, controlled powder handling, simple and verifiable cleaning, and effective prevention of cross-contamination.
The market demands tablets with consistent weight, hardness, and appearance, and therefore expects repeatable operations as a condition for competing efficiently. In international markets, the challenge for tablet presses is won by those able to produce oral solid doses with stable quality, standardized processes, and sustainable productivity.
“The tablet press market is highly competitive on a global scale, but it still offers significant growth opportunities. Oral solid doses are a clear example: tablets account for about 80% of the total. This figure highlights how strategic it is to have a strong position in this sector. That is why the company has invested in SOLIDA and DOMINA,” says Luca Cavazzini, Sales & Marketing Director at IMA Active.
Plant modularity: making the difference in dynamic markets
SOLIDA is a tablet press designed for easy production. Two models are available: SOLIDA 300 and SOLIDA 500, each with its own production requirements. (Video: IMA)
In rapidly changing markets, modularity is not a detail: it becomes an operational guarantee. “Why choose a modular plant?” explains Luca Cavazzini.
“For us, it is one of the most strategic features of our machines. Today markets change quickly, products are updated continuously, and batches are becoming increasingly variable. To keep up, you need a flexible, modular line capable of adapting to current requirements.”
“Companies must move from one format to another very quickly, and a modular line provides the reassurance of investing while knowing that the plant can be reconfigured without invasive interventions. That is why we design IMA machines already prepared for multiple configurations and easy to upgrade. It is an approach that makes it possible to offer technologically advanced solutions both to large multinationals and to medium-sized companies”.
This approach is completed by two practical advantages: managing more variants and speeding up market entry, without wasting value that has already been installed. “Modularity,” Cavazzini adds, “makes it possible to manage an enormous variety of products, formats and specifications. And this also reduces time to market, an aspect that really makes the difference today. In addition, there is an important issue: 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.”
Pharmaceuticals and nutraceuticals: growing opportunities for tablet presses
“The tablet market, which for years was almost exclusively pharmaceutical, is now opening up to new sectors,” Luca Cavazzini continues. “The nutraceutical sector, in particular, is growing very quickly and now represents a truly significant share. This is leading to increased demand for tablet presses capable of ensuring high productivity and consistent quality of the finished product. Our tablet presses are built with pharmaceutical DNA: high standards, advanced features, precise process control, and stable quality. The nutraceutical sector is moving very close to these requirements, and the gap compared to pharmaceuticals is now minimal. That is why our machines operate without problems in both fields, and nutraceuticals have become a strategic area for us. The technologies developed for pharmaceuticals perfectly meet these needs. A tablet press built according to pharmaceutical standards works without difficulty in the nutraceutical sector and even in other tablet markets, such as detergents. In this way, it offers flexibility and an excellent return on investment”.
SOLIDA 300 and SOLIDA 500: differences and production capacity of the tablet presses
SOLIDA is a tablet press designed to be easily selected and quickly put into production. It integrates innovative technical solutions to achieve excellent results.
There are two models: SOLIDA 300 and SOLIDA 500, which differ mainly in the production requirements they are able to meet:
- SOLIDA 300: from 194,000 tab/h (maximum diameter 25 mm, 27 stations) to 396,000 tab/h (maximum diameter 11 mm, 55 stations);
- SOLIDA 500: from 288,000 tab/h (maximum diameter 25 mm, 40 stations) to 576,000 tab/h (maximum diameter 11 mm, 80 stations).
Separated cleaning areas for greater hygiene and reduced cross-contamination
SOLIDA adopts a complete separation between the processing area and the mechanical area. Specially designed seals and protections create an effective barrier and, when necessary, isolation can be increased through the integration of bellows.
By reducing exposed surfaces and those in contact with the product, the tablet press simplifies cleaning operations and shortens recovery times. It reduces the risk of cross-contamination that can occur with frequent product changeovers and rapid batch changes. In addition, the protected environment preserves the machine over time: cams, tooling, and compression rollers are less stressed and maintain their performance for longer.
Fast turret changeover with HMI guidance
Downtime slows production, such as turret changeover and cleaning operations, is eliminated. The compact design makes integration into production departments easier, with an operating concept focused on maximum simplicity. One example is the full opening of the outer doors, which allows easy access to the processing area.
By reducing the surfaces in contact with the product, the tablet press shortens cleaning times and helps keep the machine efficient over the long term. The most stressed components also benefit, such as cams, tooling, and compression rollers, which can operate in more protected conditions and have a longer service life.
SOLIDA’s turret changeover is completed in just a few minutes thanks to the integrated rotating arm.
The procedure is guided by the HMI, thus reducing operational errors and increasing safety, making the changeover more controlled and repeatable. For operator well-being, the machine is equipped with effective anti-vibration solutions and sound-absorbing materials, while the fully brushless motorization helps contain energy consumption and ensure consistent performance.
MAX HMI on SOLIDA: greater operator efficiency, fast response and quick learning
MAX is IMA Active’s new standard human-machine interface installed on the machine. The system is supported by KORTEX, an iFix-based SCADA system, designed for the Internet of Things and intended to bring machine data to higher levels. In practice, connection with plant supervision and management becomes faster and more consistent, both for local integration and for comparison and alignment between different plants.
Usability comes from everyday work experience on the production floor. The interface is fast, its behavior is predictable, and it is easy to learn, reducing the operational workload and increasing safety in repetitive operations. The result is an HMI designed for the real needs of those working in production.
Automatic lubrication outside the processing area
The automatic lubrication system is housed in the base of SOLIDA. The circuit serves the upper and lower pre-compression and main compression rollers, also reaching punches and cams. The oil does not enter the processing area but is recovered in the main tank and recirculated through the circuit in a controlled manner.
In this way, lubricant consumption remains under control, the machine stays clean, and dripping from the upper punches is eliminated. The result is light maintenance, fewer interventions, and greater production continuity.
Tablets without defects
The SOLIDA tablet press is designed for defect-free production. To achieve this goal, the machine has a very robust structure and allows pre-compression and main compression forces of up to 100 kN, with the upper and lower cast-iron sections rigidly connected. This design choice maintains precision and reliability even at high production speeds.
The compression rollers have the same diameter and are fixed on both sides. In this way, compression remains constant, which is especially useful with products that are more difficult to compress and with sensitive formulations.
On the productivity side, SOLIDA is compatible with IMA 8 tooling and with segment technology. If required, silicone bellows can be integrated to further increase isolation of the processing area and reduce the risk of aesthetic defects, such as black spots on tablets.
The machine also integrates functions such as cumulative reject and sampling, which can be used for both single-layer and bilayer tablets. In-line control completes the system, supporting process stability and result repeatability.
SOLIDA is the concrete solution for those looking for a tablet press capable of standardizing solid dose production, combining robustness and ease of use, keeping quality under control, and increasing efficiency for different production environments.
