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.

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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.

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.

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.