Cleaning
- Clean tooling after every production cycle using ultrasonic systems or gentle, non-abrasive manual methods to remove powder residues, oils, and buildup.
- Use pharma-grade isopropyl alcohol (IPA) for a final wipe-down, ensuring a residue-free, fast-drying finish.
- Avoid wire brushes and harsh chemicals that can damage coatings and precision surfaces.
- Thoroughly dry all tools with compressed air to prevent rust.
- Proper cleaning preserves coating integrity and prepares tooling for thorough inspection and reuse.
Inspection
- Inspect punches and dies under proper lighting using digital microscopes or precision lenses.
- Check critical areas including the tip face, embossing, barrel, and key alignment for wear, pitting, corrosion, or micro-cracks.
- Even minor surface flaws may cause tablet weight variation, sticking, capping, or die bore damage.
- Perform inspection after cleaning and before reinstallation or repair.
- Use a standardized checklist to maintain repeatability and traceability.
- Immediately remove defective tools from production.
- This process ensures consistent tablet quality and prolonged tooling life.
Repair
- Minor surface damages such as corrosion, scratches, and wear marks are safely removed by controlled lapping, buffing, or micro-polishing.
- Repairs must be performed by trained operators to maintain functional geometry and critical tolerances.
- Select polishing compounds and abrasive films based on coating type and material hardness.
- Re-verify tools after repair to ensure no dimensional shifts or loss of concentricity.
- Proper repair extends tooling life without compromising tablet consistency or press alignment.
Measurement
- Measure every new punch and die using precision instruments to verify dimensional accuracy against approved drawings.
- Key measurement points include tip dimensions, barrel diameter, overall length, and cup geometry.
- Use digital gauges, micrometers, and height measuring tools to ensure consistency.
- Check surface quality and geometry to match design intent before coating or final inspection.
- Document all measurements for quality assurance and batch traceability.
Polishing
- Utilize automated polishing with drag finishing systems from manufacturers like Otec and Belair Finishing for consistent, repeatable surface finishes.
- Automated polishing is effective for routine surface smoothing but cannot restore worn punch cups or extend tooling life.
- Skilled manual buffing remains essential to refurbish worn punch tips, fully polish punches, and extend life—requiring proper training and technique.
- Combine both methods for high efficiency and precision in long-term tooling performance.
Lubrication
- After complete cleaning, apply a thin, uniform layer of food-grade rust preventive oil to all metal surfaces to prevent oxidation and corrosion.
- For moving parts such as punch heads or guide areas, use pharmaceutical-grade grease to reduce friction during press setup and operation.
- Only lubricants that meet pharma compliance standards should be used, ensuring they are non-reactive and leave no harmful residues.
- Before reinstalling tooling into the tablet press, carefully wipe off any excess oil to maintain clean, dry contact surfaces.
- This step protects tooling during storage and ensures smooth, consistent production performance.
Storage
- Store tooling individually in non-contact compartments such as foam-lined trays or vertical racks to avoid edge collisions.
- Follow industry standard practice by pre-lubricating with food-grade anti-rust oil and adding desiccants to control humidity.
- Categorize and label tools by type, size, and batch number for easy traceability and access.
- Use dedicated stainless steel trolleys or enclosed cabinets for safe internal transport and long-term storage.
- Maintain clean, climate-controlled storage environments, typically below 50% relative humidity (RH), to prevent corrosion and meet GMP requirements.
Weather-Proof
Packaging
Built to last. Designed to perform. Trusted by leading pharma brands.
Tools are individually placed in protective holders preventing contact and physical damage during transport.
Packaging design prioritizes safety, durability, and eco-friendliness.
Tools are sealed in moisture-resistant pouches with desiccants for humidity control during shipping.
No oil or grease is applied during packing; tools arrive clean, dry, and ready for immediate use or inspection.
Items are packed in sturdy corrugated boxes designed for protection during handling and transit.
Each box includes a tooling care manual and quality control report, accessible either via printed copy or QR code.
Customers should follow handling and storage instructions immediately upon opening to safeguard tooling integrity.
This comprehensive approach protects tooling from damage and corrosion, ensuring consistent quality from our factory to yours.
