Tableting solutions for food, chemical and industrial applications

Beyond Technology

The new business model from Romaco sets valuable incentives for meeting customer requirements. For the design of innovative solu-tions, Romaco relies on its unique knowledge portfolio.With its diverse brands, Romaco focuses on important technological fields of competence. The single product lines offer the optimum

prerequisite for the development of comprehensive solutions. Romaco promises its customers professional project handling, fast delivery times and a reliable service. Through this, Romaco provi-des its customers with a considerable boost to their earning and financial power.

Creating Value – best price/performance ratio

Romaco wins over its customers by offering an outstanding price/performance ratio over the entire life cycle of its products. In this way, customers can systematically optimise their cash flow. With efficient production and service management, Romaco prepares its customers for future long-term commer-cial success.

Delivering Solutions – high application expertise

Romaco offers integrated solutions for the growing markets of pharmaceuticals, cosmetics, food and industrial applications. Here, the customer benefits from the synergetic effects that result from the close collaboration of all the Romaco brands. This internal technology transfer imparts a con-siderable development potential and is the basis for comprehensive solutions.

Exploiting Technologies – strong brands

Romaco is synonymous with European engineering on the highest level. With its seven brands, the company is widely recog-nised around the world. Continuity and prog- ress are the keys to a strong positioning on the market. Romaco relies on the profound knowledge and the long-time experience of its employees.

Delivering Solutions Versatile tablet presses for applications in the areas of food, chemistry and industry

Tablet presses which are used in the food or chemical industry must feature great machine efficiency, high pressing forces and large production capacities. The Romaco Kilian equipment meets all of

these requirements and also offer reliability and technical highlights which provide for extremely high performance. In addition, they are perfectly suited for integration into a packaging line.

» Our applications require versatile and robust facilities which offer great production performance and high efficiency. In addition, they must be capable of being integrated into packaging lines without any problems. The tableting solutions from Romaco Kilian meet all of those requirements. «

Frank Riesner, Senior Process Engineer, Nestle Product Technology Center, Germany

Tableting machines for food applications

• For applications such as sweeteners, sugar, dextrose, fructose, stock cubes, dietary supplements

•Robust design and high reliability for the perfect processing of abrasive or hard-to-handle products

•Special filling systems: high performance even with poorly flowing products

Tableting machines for chemical applications

• For applications such as catalysts, salt tab-lets, fertilisers, pesticides, naphthalene, paints, cleaning agents, batteries, airbags

•Perfect compensation of high extraction forces

•Explosion-proof design•Adjusted machine configurations ready for

production for special chemical applica-tions

Tableting machines for individual applications

•Continuous development of new customer-specific solutions: perfect solution for customer products and their challenges

• Testing laboratory KiTech: analysis and consultation regarding product processing

Delivering Solutions Various Types of Tablets

Romaco Kilian has adapted its machines to the requirements of the chemical and food industry in an optimum way that allows for highly efficient pressing of any customer products into various tablet forms and types:

•Single-layer, double-layer and triple-layer tablets

•Core-coated tablets (Tab-in-Tab)• The shape can be freely chosen (e.g.

bone shape, faces, stars, animals)

Different application-specific filling and output systems provide for a continuously high machine performance, even with abrasive, poorly flowing and explosive pro-ducts. It is possible to press very large (> 45 mm) tablets as well as extremely small (0.8 mm) micro tablets. Different multi-tip tooling increases the output and reduces production times.

Special tablet discharge Robust designLower pressure rollers

Reliable solutions also for highly viscous materials

Romaco Kilian KTS 1000 is a very reliable tablet press and perfectly suited for appli-cations in the food and chemical industry which require compression forces of up to 120kN. The machine features an exceptional-ly robust design. Vibrations and penetration of granulate materials into the mechanical part of the machine have been minimised.

The KTS 1000 is available in two configurations• 2L (single-layer/double-layer machine)• 3L (single-layer/double-layer/triple-layer

machine)

The most important applications of the KTS 1000 at a glanceThe Kilian KTS 1000 is known for its special capacity for pressing highly viscous ma-terials perfectly. It is particularly suited for the production of tablets from corrosive, abrasive or acidic materials.

Chemicals•Dishwasher tablets•Cleaning tablets• Fertiliser•Pesticides•Naphthalene•Paint

Food•Stock cubes•Sweeteners•Dextrose• Fructose•Dietary supplements

Sintered metals, ceramics, electrics•Sintered metals•Coal products

Cosmetics•Denture cleaners•Bath salts

Flexibility• Flexible capabilities for different

applications•Suited for abrasive products

•Use of special tools for products that are difficult to press

•Optimised product feeding system for sticky and poorly flowing products

•Availability of different filling systems for optimised powder feeding

Technical highlights•High overall equipment effectiveness•Extremely robust machine design for

compression forces of up to 120 kN• Triple-layer tableting possible thanks

to three pressing stations• Large pitch circle of 840 mm for high

performance•Hydraulic overload protection

•Patented wear-free punch braking magnets for constant recirculation

•Maximum output of 3,000 (single-layer) and/or 1,500 tablets (double-layer) per minute with simple tools

•Maximum pre-pressing force and main pressing force of 120 kN

• T(otal) P(reventive) M(aintenance) design

Exploiting TechnologiesKTS 1000 series from Romaco Kilian

Exploiting TechnologiesRX from Romaco Kilian

Special machine design Hand wheelsPatented brake magnets

Double-sided rotary press for industrial and technical tableting applications

RX is a robust and reliable double-sided rotary tablet press which can be configured as single-layer or double-layer press.

The most important applicationsThis worldwide established machine type is preferred for the processing of•Chemicals (catalysts, salt tablets, fer-

tilisers, pesticides, naphthalene, paints, dishwasher tablets)

• Food (sweeteners, sugar, dextrose, fructose, dietary supplements)

•Sintered metals, ceramics, electrics (hard metals, airbags, coal products)

•Cosmetics (denture cleaners, bath salts)

Optimised overall equipment effectiveness• Minimum product loss•Extremely robust design for the

reliable compression of abrasive products•High operator convenience•Minimum demand for spare parts•High output of up to 680,000 tablets

per hour•Punch bellows for long production

processes

Technical highlights•Double-sided rotary design

for higher performance•Optimised lubricating system

for less wear•Patented wear-free punch braking

magnets for constant recirculation•Machine room separated from the

process area for easy cleaning•Different filling systems for

optimised powder feeding available•Only small floor space required which

saves space during the production• Low noise operation

Exploiting TechnologiesE150 PLUS from Romaco Kilian

HMI screen Filling systemHand wheel

High reliability at low operational costs

The E150 PLUS from Romaco Kilian offers excellent tablet quality and high reliability at low operational costs. It guarantees a high output and a long lifespan

Fast changes•Good accessibility for the

fast changing of tools•Availability of different filling systems

for optimised powder feeding•System upgrades for the operation

with IPC unit allow for a direct weight monitoring

•Monitoring of all process parameters•Operation via a 12“ touch-screen

Technical highlights •Patented wear-free punch braking

magnets for constant recirculation•Overload protection of the machine

and the tools in case of overload•High stability despite low weight •Control cabinet and HMI are integrated•Space-saving thanks to small floor space

requirements• Fitted with pre-pressing and main

pressing station •Maximum output of 225,000 tablets

per hour with 36 punches, 200,400 with 32 punches, 162,800 with 26 punches, 131,500 with 21 punches

•Special design for ring tablets•Maximum filling height 45 mm•Maximum tablet diameter up to 40 mm•Patented Kilian bellow system

Exploiting TechnologiesS250 B from Romaco Kilian

Perfect solution for the pressing of stock cubes

The S250 B is a medium-sized and very reliable tablet press for poorly flowing products.

The most important applicationsThis machine type has been especially developed for the manufacture of stock cubes and complies with the internationally established standards of the food industry.

Robust and reliable•High performance•Robust structure for reliability even under

difficult conditions such as extreme heat• “Non-stick-design” of the parts in contact

with the product•Special multi-purpose tools•Optimised product feeding system for

poorly flowing stock cube granulate• Large filling area

Technical highlights•Maximum output of up

to 1,800 tablets per minute• Filling depth of up to 45 mm• Tablet scraper and tablet discharge

optimised for stock cubes•Prepared for connection to a

packaging line•Machine in TPM design •Patented Kilian bellow system

Special tablet chute Multi-tip tooling with bellowsSight glass

Exploiting TechnologiesSTYL’ONE series from Romaco Kilian

Perfect solution for R&D applications

The Romaco Kilian STYL’ONE is a single punch tablet press which is perfectly suited for R&D applications. The machine is impressively versatile and can be used for all types of tablets. Tests can be conducted within a short time and provide extremely precise results.

STYL’ONE is available in two configurations•STYL’ONE Classic: the most flexible solu-

tion for the characterisation of the product with very good price/performance ratio

•STYL’ONE Evolution: the best easy-to-use solution with guaranteed scale-up in real-time production speed

All STYL’One presses are designed for single-layer pressing (SL) and can be easily retrofitted according to the future require-ments with multi-layer (ML), Tab-in-Tab, stearate spraying system, etc.

Technical highlights•Special filling system: pressing of up

to five layers with up to five different products

•Multi-layer tableting with a maximum output of 450 tablets per hour

•Dwell time programmable at intervals of between 5 ms and 2 s

•Pressing analysis and production optimisation with minimum quantities of product

• The pressing profiles of all tablet presses from Romaco Kilian are available, others optionally

•Extensive, specially developed “ANALIS” software for detailed pressing process analysis: easy creation of customised reports

High tech core setting unit Easy core positioningInnovative filling system

Exploiting TechnologiesKTP 180 from Romaco Kilian

Compact rotary press for R&D applications

This compact machine is the ideal solution for R&D applications and is also suited for small batch production.

Available in two configurations•KTP 180 (Laboratory)•KTP 180 (Production)

Technical highlights•Completely automated machine

without hand wheels•Operation via an integrated HMI

with 12“ touch-screen•Data capture and analysis system

integrated into the operating software•Exchangeable die table in a very

compact design•Patented wear-free braking magnets

Easy access Easy cleaning Self-explanatory menu

Creating ValueCreating Value – Romaco generates added value for the customer across the entire life cycle of its solutions

•Romaco is interested in a long-term solution partnership with its customers

•Romaco is familiar with its customers’ critical success factors throughout the different life cycle phases of our jointly developed solutions

• The range of services from Romaco is specifically designed for these phases and is delivered through the appropriate modular components

•Romaco optimises the internal process- es so that the customer can benefit from more secure decisions within the time gained

• In April 2014 the new business unit Romaco Systems was founded within the Romaco Group: the aim of this unit is to integrate the offering of the Romaco Group into comprehensive solutions

We understand the business model of our customers and with a diverse portfolio we offer the best price/perfor-mance ratio for generating additional cash flow.

Benefit for the customer

Across the entire life cycle•Minimal life cycle costs and low TCO guar-

antee fast amortisation of the financial investment

• The wide range of customer service prod-ucts ensures sustainable value creation

In the investment phase (designing value)•Professional consulting to increase deci-

sion-making security•Short processing and delivery times give

maximum scope for investment decision and thus optimum decision flexibility

•Customised solutions development for the optimum preparation of the imple-mentation phases (ramp-up and production)

•Reliable and customer-orientated proj-ect management according to efficient milestone principles provides professional delivery

In the ramp-up phase (leveraging value)• The production phase is reached more

quickly due to shortening of ramp-up• Transfer of expertise provides increased

security to the customer in implementing production systems at the highest level

•Minimisation of ramp-up costs

In the production phase (harvesting value)•Maintenance of the value stream due to

quick customer service response times•Best delivery times in service, format and

spare parts•Consulting on the optimisation of the OEE•Continuous training of the customer team•Extension of the life span

Creating Value describes our constant willingness to secure our customers’ – and our own – financial success.

Customer Service

Reliable – competent – global

From installation through the entire service life of the plant

Servicing• Telephone support: qualified and prompt

processing of issues and questions• Internet remote maintenance: digital

access for fast and safe fault diagnosis•On-site service: Romaco Kilian technicians

will be with you quickly in case of faults•Servicing contracts: preventive repair

minimises the failure rate•Calibration of the instrumentation of the

machine

Additional services at a glance: The Romaco Kilian academy: training on different levels on the following topics•Machine operation •Optimisation of the manufacturing

process•Special training for customer-related

tableting issues•Access to all fields of knowledge:

pharmaceutics, mechanics, electronics, mechatronics

Pharmaceutical manufacturers who choose Romaco Kilian get more than just a high-quality machine. The service of Romaco Kilian is based on more than 100 years of experience in tableting and goes beyond maintenance work and spare parts supply. On the basis of the expert knowledge of its staff, Romaco Kilian finds solutions even for complex applications and products and maximises production speed and product quality. For this purpose, Romaco Kilian developed the test laboratory KiTech. The laboratory comprises six press rooms with the latest technology and three conference rooms for project-related discussions and post-processing.

In the optimisation of the tableting proc-ess and troubleshooting during the tablet production, Romaco Kilian is a competent partner for its customers.

Spare parts, format parts and interchange parts •Complete quality monitoring•High percentage of internal production

with durable special materials, manufactured according to lean principles

• Fast and reliable delivery thanks to short cycle times

•Each part is tested at Romaco Kilian before delivery

•An experienced repair team repairs the parts according to the original specifications

Machine upgrades and retrofits• “Retrofit project”: state-of-the-art

electrical components for old machines• Individual solutions: customer-specific

retrofits and upgrades for every machine type

•Extensive portfolio: options for the electronic retrofitting and controller upgrades

• Local flexibility in the design of the upgrades: on-site or at Romaco Kilian in Cologne

Startup•Startup and instruction of the operating

personnel•Support for the validation•Ramp-up service: immediate achievement

of the highest degree of efficiency with the new equipment

KILIAN Tableting GmbHScarletallee 1150735 KölnGermany

T +49 (0)221 7174 100F +49 (0)221 7174 110E kilian@romaco.com

www.romaco.com