NexGen Press® range
NexGen Press® 45
The NexGen Press® 45 represents the ultimate combination of modular design, digitization, safety, ease of use and ergonomic functionality, while providing high throughputs for larger tablet production campaigns.
To respond to present and future market demands, manufacturers are looking for flexible and multifunctional solutions that can handle both low and high potency active ingredients. This next generation of modular tablet presses will make machine selection easier, facilitate fast product changeovers and deliver price-performance leadership. Offering operational excellence, each NexGen Press® is intuitive, simple to use and benefits from a back-to-basics design philosophy. And, of course, like any GEA press, safety, robust functionality, support and customer service come as standard.
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.
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.
Better Together: Innovation and Sustainability
Initially, the high-throughput NexGen Press® 45 was tested in standalone mode and compared with a MODUL S machine. Following a series of trials, TÜV representatives certified that, in terms of electric power usage, operational utility savings of up to 27% could be made. This result builds on the performance of the inaugural NexGen Press® 30 model that, in 2023, was also awarded an Add Better label for average power savings of 21% (compared with a base machine configuration).
Subsequently, data from the NexGen Press® 45 test was combined with supplementary statistics (derived from the feeders and blenders) from a ConsiGma® CDC200 Continuous Direct Compression model. When adjusted to accurately represent the correct operational setup and theoretical power consumption, energy savings of 30% were calculated (compared with a MODUL-equipped CDC50 combination).
A perfect blend of physical and digital
The patented Exchangeable Compression Module (ECM) concept not only provides improved containment and has a lower product-contact area compared with other models on the market, it is also WIP/WOL-compatible and facilitates fast changeovers in a small footprint, high-output rotary tablet press with multiple compression modes.
Modular by design, every NexGen Press® can be customized to fit specific applications — for now or the future — with predefined option packs. Examples include bilayer and MUPS tablets, poorly flowing powders, small volume/high yield products and those that require antisticking solutions.
Additional features such as punch face lubrication (iSpray), an intermittent cleaning system, A2D tooling for increased capacity, PAT integration and UL certification are also available.
For ongoing peace of mind, out-of-the-box training and support is always on hand. GEA offers immersive tuition via virtual reality, support intervention via a two-way remote support link, built-in preventive maintenance and a QR code system for spare parts.
Specifications
NexGen Press® 45
| Tooling | D | B | BB | BBS | A2D |
|---|---|---|---|---|---|
| EU / TSM | EU / TSM | EU / TSM | EU / TSM | EU / TSM | |
| Max. tablet diameter [mm] | 25.4 | 16 (L=19) | 13 (L=14,3) | 11 | 11 |
| Punch body diameter [mm] | 25.4 | 19 | 19 | 16 | 12 |
| Outside die diameter [mm] | 38.1 | 30.16 | 24 | 22 | 38.1 |
| Die height [mm] | 23.81 | 22.22 | 22.22 | 22.22 | 23.81 |
| Number of punch positions (Dies/Segments) | 34/39 | 42/51 | 48 | 54 | 72/72 |
| Max. fill depth [mm] | 20 | 19 | 19 | 19 | 19 |
| Top punch penetration [mm] | 1 to 4 | ||||
| Bi-layer: Top punch penetration 2nd layer [mm] | 9 | ||||
| Max. pre-compression force [kN] | 10 | ||||
| Bi-layer: Max. 1st layer pre-compression force [kN] | 2,5 | ||||
| Bi-layer: Max. final pre-compression force [kN] | 10 | ||||
| Max. main compression force [kN] Single & Bi-layer | 100 | ||||
| Max. output capacity [tab/h] - dies | 183,600 | 302,400 | 345,600 | 388,800 | 518,400 |
| Bi-layer: Max. output capacity [tab/h] - dies | 61,200 | 100,800 | 115,200 | 129,600 | 172,800 |
| Max. output capacity [tab/h] - segments | 210,600 | 367,200 | - | - | 518,400 |
| Bi-layer: Max. output capacity [tab/h] - segments | 70,200 | 122,400 | - | - | 172,800 |
| Electrical requirements |
3phase+PE – 380V - 480 V – 50Hz / 60Hz (nominal consumption 7 kW; power installed 13 kVA) 1phase+PE – 200V - 240 V – 50Hz / 60Hz (nominal consumption 0.5 kW; power installed 1.4 kVA) |
||||
| Compressed air requirements | clean & dry / 7-8 bar / 500l/m peak - 100l/m average | ||||
| Dust extraction requirements | 150 m³/h at 15 mbar | ||||
| Machine dimensions & weight | W = 1474 mm x D = 1364 mm x H = 2390 m – 3800 kg | ||||
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