Manesty's Service for the industry

Although machinery manufacturers would like companies to buy new machines, in the current economic climate this is not always possible. Manesty* has developed an alternative solution

Late in 1999, Manesty, one of the world's leading manufacturers of pharmaceutical industry tablet presses and tablet coating machines, re-structured its after-market business unit. This followed the appointment of Kevin Costello to the management board as director of the after-market unit.

One of Costello's first priorities was to establish a team dedicated to the refurbishment of Manesty tablet presses and tablet coating machines.

There are many such machines operating day in, day out in the pharmaceutical and other industries, which are fundamentally sound but have become less accurate with age.

A testament to the success of this new operation is one of the first machines to be refurbished. The task was undertaken on a type D4 Manesty tablet press belonging to Thompson & Capper.

Thompson & Capper, part of the Irish conglomerate DCC Group, is a contract tablet maker and also a manufacturing chemist. It has been based at its current Runcorn site for the past 20 years, employing around 80 people who are collectively responsible for an output of roughly one billion tablets and capsules a year.

Thompson & Capper offers the complete service from sourcing the ingredients, blending the formulations, tablet pressing, tablet coating, hard gelatine capsule filling, blister packing and pot filling. It operates more than 30 tablet presses in total, all of which are manufactured by Manesty — as in fact are two recently acquired tablet coating machines. The company specialises in the production of otc medicines, vitamins, minerals and supplement products for a host of customers worldwide.

Given its two shift working day and typically 70% plus machine loading, the process equipment endures a relentless onslaught of activity. The Manesty tablet presses are no exception.

The D4 tablet press in question had been in constant use since its purchase from Manesty in 1996 for the manufacture of desiccant tablets — part of a pregnancy test kit.

Having been made aware of Manesty's refurbishment service, it was decided to have the press overhauled at the end of the contract for the pregnancy test tablet. The over-loaded tablet press was to be relocated into the pharmaceutical tabletting facility. It was essential that the overhaul ensured that the press was operating perfectly — to the exacting standards needed in the industry.

Kevin Fairhurst, production manager at Thompson & Capper, decided to put Manesty to the test — especially given the considerable cost saving compared with a completely new press. As he confirmed, 'Much of the machine was still in good working order. Things like support castings last "forever".

'It was just the operating parts, subject to normal wear and tear, that needed replacement, and who better to do the job that the original manufacturer.'

The refurbished D4 press has been in operation for over 12 months now and is giving sterling service alongside its fellow Manesty presses. As production supervisor, Norman Travis, confirms, 'We are very happy with Manesty's service on this job, and elsewhere too. Our D4 machines are excellent, reliable general purpose work horses. They are so easy to clean. This is important, given that some runs only last two to three days, although some last three months.'

As Manesty's after-market development manager, Duncan Turner, confirms, 'This particular machine was not as old as many but it was given a tough time. Even so, it only required what we call an intermediate refurbishment.

'This included the replacement of cams, pressure rolls and other general wear and tear parts.

'We were able to re-work the machine turret offering Thompson & Capper a considerable cost saving on a full replacement. In addition, our customer took advantage of our offer to upgrade the press by adding an "Autofil" powder transfer unit and a tachometer.'

Travis adds, 'The Autofil powder transfer unit makes loading the press quicker, more hygienic and more efficient. The tachometer enables us to record the optimum speeds for specific jobs. This enables us to re-set the same criteria for repeat contracts and to get closer to the ideal speed for similar jobs, thus reducing set up times and product wastage.'

Turner is rightly enthusiastic about Manesty's new service. 'The Thompson & Capper contract was one of our first. Depending on the clients' needs, we offer three levels of service.' These are: