NexGen Press® range
NexGen Press®
Designed to align with GEA’s initiative to “drive product innovation with digitalization and a focus on the environment,” the NexGen Press® range represents the future of tablet compression for the pharmaceutical industry.
Building on a legacy of success
When designing the NexGen Press®, the best features of the previous ranges were kept, as they have proven to be invaluable in terms of enhancing productivity and flexibility.
For example, the unique Air Compensator technology — fitted to the pre- and main compression stations of every machine in the NexGen Press® range — allows to run the machine using either the industry-standard force control for weight and hardness, or to use one of the additional five compression modes. These compression modes, depending on how the air compensator is used during pre- and main compression, help to reduce capping, sticking and overcome other common production issues.
Flexibility comes as a standard
Modular by design, every NexGen Press® can be configured to fit specific applications — for now or the future — with predefined option packs:
- Low Volume/High Yield Pack: ideal for processing small amount of product.
- Poor Flow Pack: to ensure even poorly flowing products can be compressed without issues
- Bilayer Pack: after an easy 1-time mechanical upgrade, you can turn your mono-layer tablet press into a bilayer tablet press (and vice-versa) within the hour
- Microtablets Pack: optimized set-up to produce microtablets
- OEB3 Pack: turns your basic GMP press into one suitable for producing OEB3 products
- OEB3 Wet Down pack: enhancement of the OEB3 Pack to include inline or offline wetting of the product contact parts.
- OEB4-5 Pack: apply the highest levels of containment performance on your NexGen Press®
- OEB4-5 Wash pack: addition to the OEB4-5 Pack offering a full solution to wash the product contact parts inline or offline
- MUPS Packs (Functional and Prime Pack): depending on the specific needs of your MUPS Production, special features can be added to optimize yield
- UL Certification Pack
Additional features such as punch face lubrication (iSpray), A2D tooling for increased capacity and PAT integration are also available.
The ECM Concept
From Fast-Change-overs to the highest containment level
Based on more than 20 years of industry expertise, the patented FAST CHANGEOVER Exchangeable Compression Module (FCO ECM) provides at-source containment and has at least a 50% smaller product-contact area compared with other models on the market.
Much more than a conventional exchangeable turret, the ECM is a sealed unit that’s isolated from the remainder of the tablet press and not only contains the turret and compression tooling, but all the press’s product-contact parts as well. At the end of a production run, the ECM can be removed from the machine in just 15 minutes. A duplicate, clean ECM can then be installed in the machine in another 15 minutes.
The ECM facilitates fast changeovers and enhanced operator and product safety, making the NexGen Press® range both efficient and versatile. It also benefits from multiple compression modes and a small footprint.
To respond to the increasing market demand for containment solutions, the standard FCO-ECM can be upgraded to allow you to produce OEB3 and/or significantly diluted highly potent products.
For high-containment applications, a stainless-steel version of the ECM (FCO HC-ECM) is available with a WOL or WIL pack, depending on customer requirements. This FCO HC-ECM is intended for OEB4–5 products such as oncology drugs and hormones.
At a glance.
Performance
- Intuitive, safe and simple to use
- Back to basics design philosophy
- Plug and play functionality for a wide range of applications
- Higher productivity levels and superior tablet quality
- Cost-effective operation
- ECM offers fast changeovers and a range of containment levels from standard production to OEB5
- A2D tooling
Modular
- Dust-tight to OEB5 containment on a single platform
- The first press range to offer both Wash Offline (WOL) and Wash Inline (WIL) functions
- Fully customizable to accommodate MUPS, orodispersible, bilayer tablets and more
Digital
- Digitalized and Pharma 4.0-compatible
- Delivered with GEA’s latest control system (MC5i)
- Compatible with the Digital Canary product leak detection system
- Virtual training, app-based support and online assistance available
Environmental
- Small footprint
- Energy-efficient operation*
Future Perfect
- Easy to integrate into continuous manufacturing lines
One Machine. Many Applications.
Examples include high-volume generics, analgesics, anti-inflammatories, metformin, ibuprofen, paracetamol, effervescents, nutraceuticals and vitamins, antibiotics and penicillin, orodispersible tablets, MUPS and bilayer tablets, hormones and oncology products, orphan drugs and new chemical entities (small volume/high yield), microtablets, poorly flowing powders, heat- and moisture-sensitive products and those that require capping and/or antisticking solutions.
* NexGen Press® 30 and NexGen Press® 45 have been awarded the Add Better label for energy efficiency. For more details, check the specific product pages.
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