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How a leading pharmaceutical manufacturer in Gazipur, Bangladesh upgraded from manual legacy presses to dual RTP-35 Rotary Tablet Presses, increasing batch throughput by 42% while reducing weight variation RSD to under 1.1%.
Three ageing 16-station single-rotary presses capped output at 1.2 million tablets per 8-hour shift. Tablet weight RSD ran above 3.2%, causing frequent manual adjustment and batch holds, and capping rose during the monsoon months as room humidity drifted.
Two RTP-35 double rotary tablet presses with force feeders, pre-compression and automatic weight control driven by compression force measurement, fed by a VTS-500 vacuum conveying system from intermediate bulk containers. GentlemanPharmed executed SAT and the IQ/OQ protocols on site.
42%
increase in output per 8-hour shift
1.08%
tablet weight RSD, down from 3.2%
62%
reduction in tooling changeover time
BD Pharmaceuticals, a prominent generic drug manufacturer based in Gazipur (near Dhaka, Bangladesh), was experiencing production bottlenecks across their high-volume Paracetamol 500 mg and Metformin 850 mg lines.
Operating on ageing 16-station single rotary tablet presses, the facility faced:
In collaboration with the plant engineering leadership, GentlemanPharmed deployed a turnkey tableting upgrade package:
| Performance Metric | Baseline (Legacy Press) | Post-Upgrade (RTP-35 Lines) | Improvement | |---|---|---|---| | Shift Output (8 Hours) | 1.20 Million Tablets | 1.71 Million Tablets | + 42.5% | | Tablet Weight RSD | 3.2% | 1.08% | 66% Variance Reduction | | Capping / Defect Rejections | 1.8% of batch | < 0.05% | 97% Defect Reduction | | Cleanroom Tooling Changeover | 120 minutes | 45 minutes | 62% Faster Turnaround |
"The commissioning team from GentlemanPharmed executed our SAT and IQ/OQ protocols in under five days. The RTP-35 machines have been running two consecutive shifts daily with zero unpredicted downtime over the past 14 months." — Engr. Tariqul Islam, VP Manufacturing Operations, BD Pharmaceuticals
High-speed 35-station double rotary tablet press with 100 kN main compression, force feeder, and automated weight regulation for continuous pharmaceutical tableting.
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