Ayurvedic Tablet Dies and Punches Manufacturer | EMMKAY INDUSTRIES

EMMKAY INDUSTRIES manufactures specialized tablet dies and punches for ayurvedic and herbal tablet production. Since 1983, we have worked with ayurvedic manufacturers across India to develop tooling solutions that handle the unique challenges of herbal formulations.

Ayurvedic tablet manufacturing is fundamentally different from pharmaceutical production. Herbal formulations contain plant extracts, gums, resins, and natural binders that are stickier, more abrasive, and more corrosive than synthetic pharmaceutical ingredients. Standard tooling often fails within weeks when used with ayurvedic formulations. Our tooling is specifically designed to overcome these challenges.

Whether you manufacture Triphala, Ashwagandha, Giloy, Tulsi, or any other ayurvedic formulation, EMMKAY INDUSTRIES provides tooling that delivers consistent tablet quality with extended tooling life.

Challenges of Ayurvedic Tablet Manufacturing

Ayurvedic formulations present unique tooling challenges that standard pharmaceutical tooling cannot handle:

Sticking and Picking: Herbal extracts contain natural sugars, gums, and resins that stick to punch faces. This causes tablets to stick to the upper punch during ejection, resulting in rough tablet surfaces, broken tablets, and production downtime. Standard chrome-plated punches often fail within days with sticky ayurvedic formulations.

Corrosion: Many ayurvedic ingredients are acidic or contain moisture-attracting compounds. Amla (Indian gooseberry), for example, is highly acidic and corrodes standard tool steel rapidly. Tooling used for such formulations requires enhanced corrosion resistance.

Abrasion: Herbal powders often contain silica, calcium, and mineral compounds that are highly abrasive. These ingredients wear down punch tips and die bores faster than typical pharmaceutical excipients, reducing tooling lifespan significantly.

Inconsistent Granulation: Ayurvedic granules tend to be less uniform than pharmaceutical granules, leading to weight variation, capping, and lamination problems. Tooling geometry and surface finish play a critical role in managing these issues.

Our Ayurvedic Tooling Solutions

Anti-Stick Coatings for Herbal Formulations:

DLC (Diamond-Like Carbon) Coating: The best solution for sticky ayurvedic formulations. DLC creates an ultra-smooth, non-stick surface that dramatically reduces sticking and picking. Recommended for Triphala, Ashwagandha, and other resin-rich formulations.
Chrome Plating with Mirror Polish: Our standard anti-stick treatment. Chrome plating combined with mirror polishing (Ra 0.1μm) reduces sticking for moderately sticky formulations.
TiN (Titanium Nitride) Coating: Combines anti-stick properties with enhanced wear resistance. Good for formulations that are both sticky and abrasive.

Corrosion-Resistant Materials:

HCHC with CrN Coating: High chromium steel with chromium nitride coating provides both wear resistance and corrosion protection. A cost-effective alternative for mildly corrosive formulations.

Optimized Punch Geometry:

Shallow concave punch tips reduce sticking compared to deep concave designs
Tapered die bores improve tablet ejection for sticky formulations
Increased land area on punch tips distributes compression force more evenly

Why Choose EMMKAY INDUSTRIES for Ayurvedic Tooling

Understanding of Ayurvedic Formulations: Unlike tooling suppliers who only serve pharmaceutical companies, we have decades of experience working specifically with ayurvedic manufacturers. We understand the challenges of herbal formulations and recommend the right materials, coatings, and geometries for your specific products.

40+ Years of Manufacturing Experience: Founded in 1983, EMMKAY INDUSTRIES has the expertise to solve even the most difficult tooling challenges. Our team has worked with hundreds of ayurvedic formulations and knows what works.

Cost-Effective Solutions: We offer multiple coating and material options at different price points. Not every ayurvedic formulation needs DLC coating — we help you choose the most cost-effective solution for your specific needs.

Quick Delivery: Standard ayurvedic tooling sets delivered in 10-15 working days. Emergency replacements available for production-critical situations.

Technical Support: Our engineers help you troubleshoot sticking, picking, capping, and other tablet defects specific to ayurvedic formulations.

Frequently Asked Questions - Ayurvedic Tablet Dies and Punches

Q: Why do my ayurvedic tablets stick to the punches?
A: Sticking in ayurvedic tablets is caused by natural sugars, gums, and resins in herbal extracts. Solutions include DLC-coated punches, mirror-polished punch tips, shallow concave punch geometry, and optimizing your formulation's moisture content and lubricant levels.

Q: Which coating is best for ayurvedic tablet tooling?
A: DLC (Diamond-Like Carbon) coating is the best option for sticky ayurvedic formulations. It provides the lowest friction surface and dramatically reduces sticking. For moderately sticky formulations, chrome plating with mirror polish is a cost-effective alternative.

Q: How long does ayurvedic tablet tooling last?
A: Tooling lifespan varies significantly with ayurvedic formulations. Standard OHNS tooling may last 1-3 million tablets with herbal formulations (compared to 3-5 million with pharmaceutical formulations). DLC-coated HCHC tooling can extend this to 3-5 million tablets. Proper cleaning after every batch is essential.

Q: Can you make tooling for large ayurvedic vati tablets?
A: Yes. We manufacture tooling for ayurvedic vati tablets up to 25mm diameter using B tooling standard. Large flat-faced round punches are our most common ayurvedic tooling configuration.

Q: Do you supply tooling for ayurvedic tablet presses from Indian manufacturers?
A: Yes. We supply tooling compatible with all Indian tablet press manufacturers