Tablet Tooling for Ayurvedic and Herbal Products | Expert Guide

Ayurvedic and herbal tablet manufacturing is one of the fastest-growing segments in India's pharmaceutical industry. As traditional formulations move from powders and pastes to compressed tablets, manufacturers face unique tooling challenges that do not exist in conventional pharmaceutical production.

This guide addresses the specific problems ayurvedic and herbal formulations cause for tablet dies and punches, and provides practical solutions based on our 40+ years of experience supplying tooling to this industry.

Why Ayurvedic Formulations Are Challenging for Tooling

Ayurvedic and herbal formulations differ fundamentally from conventional pharmaceutical formulations:

Problem 1 — Sticking and Picking

The Problem:

Herbal extracts are often hygroscopic (they absorb moisture from the air) and contain natural gums, resins, and sticky compounds. These ingredients adhere to punch faces during compression, causing:

• Tablets with rough, incomplete surfaces

• Material building up on punch tips over time

• Picking in embossed areas (letters and logos)

• Increasing frequency of press stoppages for cleaning

  
  

The Solution:

Our Recommendation: For severely sticky ayurvedic formulations, DLC-coated punches are the most effective solution. The investment pays for itself through reduced downtime, less material waste, and longer intervals between press cleaning. For moderately sticky formulations, chrome-plated punches with mirror-polished tips provide a cost-effective alternative.

Problem 2 — Corrosion

The Problem:

Many ayurvedic ingredients are acidic or contain compounds that corrode standard carbon steel tooling:

• Amla (Indian gooseberry) — highly acidic

• Triphala — contains acidic fruit extracts

• Citrus-based formulations — citric acid corrodes steel

• Fermented preparations (asava, arishta) — acidic compounds

Corrosion causes pitting on punch surfaces, which then causes sticking (creating a vicious cycle), and eventually makes the tooling unusable.

The Solution:

Our Recommendation: For formulations with known corrosive ingredients, EMMKAY Special Steel provides the best long-term value. For mildly corrosive formulations, OHNS with CrN coating is a cost-effective alternative.

Critical Practice: Clean tooling immediately after every production run. Do not leave herbal residue on tooling overnight — corrosion begins within hours for acidic formulations.

Problem 3 — Weight Variation

The Problem:

Ayurvedic granulations are often less uniform than pharmaceutical granulations due to:

• Fibrous plant materials that do not granulate evenly

• Variable particle size distribution

• Hygroscopic ingredients absorbing moisture and changing flow properties

• Natural ingredient variability between batches

Poor flow into the die cavity causes inconsistent fill weights and tablet weight variation.

The Solution:

While weight variation is primarily a formulation and granulation issue, tooling can help:

• Use dies with proper bore finish (Ra ≤0.4μm) for consistent powder flow

• Ensure die bore dimensions are within tight tolerance (±0.01mm)

• Consider force-feed systems on your press (not a tooling change, but effective)

• Use shallow concave punch tips rather than deep concave — they compress fibrous materials more evenly

Problem 4 — Capping in High-Fiber Formulations

The Problem:

Ayurvedic formulations containing high-fiber plant materials (isabgol, ashwagandha root powder, shatavari) are prone to capping — the top layer of the tablet separating during or after compression.

The Solution:

• Use beveled-edge punch tips — the bevel reduces the shearing force at the tablet edge

• Ensure proper pre-compression on your press (reduces air entrapment)

• Consider shallow concave tips instead of flat-faced tips

• Ensure die bores are not worn (worn bores trap air)

Recommended Tooling Specifications for Ayurvedic Tablets

Based on our experience with hundreds of ayurvedic manufacturers, here are our standard recommendations:

For Standard Ayurvedic Tablets (moderate stickiness, non-corrosive):

• Material: OHNS

• Coating: Chrome plating

• Surface finish: Ra ≤0.2μm (mirror polish on tips)

• Tooling standard: D tooling (most common)

For Sticky Ayurvedic Tablets (herbal extracts, hygroscopic ingredients):

• Material: OHNS or EMMKAY Special Steel

• Coating: DLC on punch tips

• Surface finish: Ra ≤0.1μm

• Tooling standard: D tooling

For Corrosive Ayurvedic Tablets (acidic ingredients, amla, triphala):

• Material: EMMKAY Special Steel

• Coating: CrN or DLC

• Surface finish: Ra ≤0.2μm

• Tooling standard: D tooling

For Large Ayurvedic Tablets (churna tablets, vati over 13mm):

• Material: OHNS or HCHC

• Coating: Chrome or DLC as needed

• Tooling standard: B tooling (for tablets over 13mm)

Common Ayurvedic Tablet Shapes

Maintenance Tips Specific to Ayurvedic Tooling

1. Clean immediately after every run — herbal residue is more corrosive and sticky than pharmaceutical residue

2. Use warm water first — many herbal extracts dissolve better in warm water than in solvents

3. Follow with IPA wipe — removes remaining residue and moisture

4. Oil immediately — do not let cleaned tooling sit unprotected, even for an hour

5. Store in low-humidity environment — herbal residue attracts moisture even after cleaning

6. Inspect tips more frequently — ayurvedic formulations cause faster wear than standard pharma

Conclusion

Ayurvedic tablet manufacturing demands tooling that can handle sticky, corrosive, and fibrous formulations. The right combination of material, coating, and surface finish eliminates most production problems and extends tooling life significantly.

EMMKAY INDUSTRIES has been supplying tooling to ayurvedic manufacturers since 1983. We understand the unique challenges of herbal formulations and provide tooling solutions that work. Contact us to discuss your specific requirements.