Customized Tablet Dies and Punches | EMMKAY INDUSTRIES

Every tablet manufacturer has unique requirements. Whether you need a custom tablet shape for brand identity, logo embossing for product recognition, or specialized coatings for difficult formulations, EMMKAY INDUSTRIES designs and manufactures fully customized tablet dies and punches to your exact specifications.

Since 1983, we have produced thousands of custom tooling sets for pharmaceutical, nutraceutical, ayurvedic, and confectionery manufacturers. Our in-house design and manufacturing capabilities allow us to deliver custom tooling from concept to finished product in as little as 7 working days. Our commitment to quality materials ensures durability, reliability, and longevity, making them ideal for high-volume production.

Custom Tooling Capabilities

How Custom Tooling Works — Our Process

Step 1: Share Your Requirements
Send us your tablet design — a sketch, CAD drawing, sample tablet, or even a description of what you need. Include tablet dimensions, shape, any embossing or engraving details, and your tablet press model. View our sample CAD drawings for reference.

Step 2: Design Review
Our engineering team reviews your design for manufacturability. We check that the shape can be compressed properly, that embossing depth is appropriate, and that the tooling will work with your press. We provide feedback and a detailed drawing for your approval.

Step 3: Prototype Manufacturing
Once you approve the design, we manufacture a prototype set. For standard customizations (embossing, break lines), this takes 10-15 working days. Complex custom shapes may take 15-21 working days.

Step 4: Sample Tablets and Approval
You run trial compressions with the prototype tooling. If adjustments are needed, we modify the tooling based on your feedback.

Step 5: Production Order
After approval, we manufacture your full production order. Repeat orders are faster since we retain your tooling specifications on file.

Custom Shape Design Guidelines

For the best results with custom-shaped tablets, keep these guidelines in mind:

- Minimum wall thickness: 1.5mm at the thinnest point to prevent tablet breakage
- Avoid sharp internal corners: Rounded corners reduce stress concentration and improve tablet integrity
- Consider ejection: The shape must allow clean ejection from the die — avoid undercuts or extreme concavities
- Embossing depth: 0.3mm to 0.8mm is typical. Deeper embossing requires more compression force
- Symmetry helps: Symmetrical shapes compress more evenly, though asymmetric shapes are possible with keyed punches

We can work from:
- Hand sketches or drawings
- CAD files
- Sample tablets from competitors (for reference only)
- Verbal descriptions — our designers will create the drawing

Common Custom Tooling Applications

Pharmaceutical:
- Company logo on one face, dosage strength on the other
- Break lines for dose splitting
- Unique shapes for anti-counterfeiting and brand recognition

Nutraceutical:
- Brand logos on vitamin and supplement tablets
- Custom shapes for product differentiation on retail shelves

Confectionery:
- Fun shapes — animals, fruits, characters, holiday themes. Popular options include star shape, moon shape, fish shape, and bottle shape
- Brand logos on candy and mint tablets
- Multi-color tablet designs (requires multi-layer compression)

Ayurvedic:
- Traditional symbols or text embossed on herbal tablets
- Custom sizes for traditional dosage forms

Custom tooling is available in D tooling, B tooling, and BB tooling standards. Standard shapes like round and capsule shape can also be customized with embossing and break lines.

Frequently Asked Questions

Q: What is the minimum order quantity for custom tooling?
A: We accept orders starting from 10 sets (10 upper punch + 10 lower punch + 10 die).

Q: Can you replicate a competitor's tablet shape?
A: We can manufacture tooling to produce a similar shape based on a sample tablet, but we do not copy patented or trademarked designs. We recommend creating a unique shape for your brand.

Q: How much does custom tooling cost compared to standard tooling?
A: Custom tooling typically costs 30-60% more than standard round tooling, depending on the complexity of the shape and embossing. Logo embossing on standard shapes adds a smaller premium.

Q: Do you keep my custom design on file for repeat orders?
A: Yes. We retain all custom tooling specifications and drawings. Repeat orders are manufactured to the same specifications and typically ship faster.

We also offer multi-tip configurations for custom shapes to increase your production output. Contact us to discuss your requirements.