Guide to Multi-Tip Tablet Punches: Double Your Output

Multi-tip tablet punches are one of the most effective ways to increase tablet production without purchasing additional presses. A single multi-tip punch produces 2, 3, 4, or more tablets per compression cycle — multiplying your output per press revolution by the number of tips.

This guide explains how multi-tip punches work, when they make sense, what configurations are available, and how to calculate the return on investment.

How Multi-Tip Punches Work

A standard single-tip punch has one tip that enters one die to produce one tablet per compression cycle. A multi-tip punch has multiple tips, each entering its own die, producing multiple tablets simultaneously.

Single-Tip vs Multi-Tip:

How It Works:

• The turret has multiple die bores per station instead of one

• Each multi-tip punch has tips aligned with each die bore

• During compression, all tips compress simultaneously

• Each tip produces an identical tablet

• All tablets from one station are ejected together

The press speed (RPM) stays the same, but each revolution produces 2x, 3x, or 4x more tablets.

Multi-Tip Configurations Available

The number of tips possible depends on the tablet diameter and the tooling standard:

D Tooling (38.10mm die OD — LARGEST standard):

Key Rule: Smaller tablets allow more tips per punch. The practical limit is determined by the die table area available per station and the minimum wall thickness between die bores.

Benefits of Multi-Tip Punches

1. Dramatically Increased Output

The most obvious benefit. A 2-tip configuration doubles your output. A 3-tip configuration triples it. For a 45-station press running at 40 RPM:

• Single-tip: 45 × 40 = 1,800 tablets/minute = 108,000/hour

• 2-tip: 45 × 40 × 2 = 3,600 tablets/minute = 216,000/hour

• 3-tip: 45 × 40 × 3 = 5,400 tablets/minute = 324,000/hour

2. No Additional Press Required: Buying a new tablet press costs lakhs or crores. Multi-tip tooling costs a fraction of that and achieves similar output increases.

3. Same Floor Space: No additional factory space needed — you are getting more output from existing equipment.

4. Lower Cost Per Tablet: More tablets per hour from the same press means lower manufacturing cost per tablet (labor, electricity, overhead are spread across more tablets).

Limitations and Considerations

Multi-tip punches are not suitable for every application. Consider these factors:

1. Tablet Size Limitation: Multi-tip configurations only work for smaller tablets. Tablets above 10mm diameter in D tooling are generally limited to single-tip.

2. Shape Limitations: Round tablets are the easiest and most common multi-tip shape. Non-round shapes (capsule, oval, custom) are possible but more complex and expensive to manufacture.

3. Higher Tooling Cost: Multi-tip tooling costs 2-4x more per set than single-tip tooling because:

• More complex manufacturing (multiple tips must be precisely aligned)

• Multiple dies per station

• Tighter tolerances required (all tips must produce identical tablets)

4. Tablet Uniformity Requirements: All tips on a multi-tip punch must produce tablets with identical weight, hardness, and dimensions. This requires:

• Precise tip-to-tip alignment

• Identical cup depths across all tips

• Uniform die bore dimensions

• Consistent compression force distribution

5. Press Compatibility: Not all presses can accept multi-tip tooling. The press must have:

• Die table designed for multiple die bores per station

• Adequate compression force for multiple tablets simultaneously

• Feed frame capable of filling multiple die cavities evenly

Check with your press manufacturer or contact us before ordering multi-tip tooling.

6. Formulation Sensitivity: Some formulations do not compress well in multi-tip configurations due to uneven die filling. Formulations with poor flow properties may produce weight variation between tips.

ROI Calculation — Is Multi-Tip Worth It?

Scenario: Pharmaceutical manufacturer producing 6mm round tablets

B Tooling (30.16mm die OD — MEDIUM standard):

Note: Prices are illustrative. Contact EMMKAY INDUSTRIES for actual pricing.

In this example, the tooling cost is the same, but the manufacturer saves 62 press-hours per 10 million tablets — worth over ₹1.2 lakh in operating costs. For high-volume production, the savings are even more significant.

When Multi-Tip Makes Financial Sense:

• You produce more than 1 million tablets per day of a single product

• Your tablets are 9mm or smaller (D tooling) or 13mm or smaller (B tooling for multi-tip)

• Your press is compatible with multi-tip tooling

• Your formulation flows well and compresses consistently

Quality Control for Multi-Tip Production

Maintaining tablet quality with multi-tip tooling requires additional attention:

Weight Uniformity:

• Check tablet weights from individual tips (not just the average)

• Weight variation between tips should be within ±2%

• If one tip consistently produces heavier or lighter tablets, the tooling or die may need adjustment

Hardness Uniformity:

• Test hardness from tablets produced by each tip

• Variation should be within your specification

• Uneven hardness indicates uneven compression force distribution

Visual Inspection:

• Check tablets from all tips for surface defects

• Sticking or picking on one tip but not others indicates a specific tip issue

Dimensional Checks:

• Verify tablet diameter and thickness from each tip

• All tips should produce dimensionally identical tablets

Ordering Multi-Tip Tooling from EMMKAY INDUSTRIES

To order multi-tip tooling, provide:

• Tablet press brand and model — we verify multi-tip compatibility

• Tablet diameter and shape — determines maximum tips possible

• Current tooling standard — D, B, BB, or DB

• Desired number of tips — we confirm feasibility

• Formulation details — helps us recommend material and coating

• Quantity of sets — we provide volume pricing

We manufacture multi-tip tooling in all materials (OHNS, HCHC, S7, EMMKAY Special Steel) and with all coatings (chrome, DLC, TiN, CrN).

Conclusion

Multi-tip tablet punches are a proven way to multiply production output from existing presses. For small tablets in high-volume production, they offer the best return on investment of any single tooling upgrade. The key is ensuring your press is compatible, your tablet size allows multiple tips, and your formulation compresses consistently.

EMMKAY INDUSTRIES has been manufacturing multi-tip tooling since 1983. Contact us to discuss whether multi-tip punches are right for your production line.