Case Study: Scaling Solid Dosage Tableting Capacity at BD Pharmaceuticals (Dhaka Plant)

## Background & Operational Challenge BD Pharmaceuticals, a prominent generic drug manufacturer based in Gazipur (near Dhaka, Bangladesh), was experiencing production bottlenecks across their high-volume Paracetamol 500 mg and Metformin 850 mg lines. Operating on ageing 16-station single rotary tablet presses, the facility faced: * Average tablet weight relative standard deviation (RSD) exceeding **3.2%**, leading to frequent manual weight adjustments and batch holds. * Persistent tablet capping during monsoon months due to ambient cleanroom humidity fluctuations. * Maximum plant throughput capped at 1.2 million tablets per 8-hour shift across three parallel lines. --- ## The Engineering Solution In collaboration with the plant engineering leadership, GentlemanPharmed deployed a turnkey tableting upgrade package: 1. **Installation of Two RTP-35 Double Rotary Tablet Presses:** Configured with Euro-B tooling (35 stations each), dual variable-speed force feeders, and integrated 20 kN pre-compression rollers. 2. **Automated Mean Weight Control Loop:** Real-time strain gauge load cells measuring individual punch compression forces, linked directly to automatic servo-driven dosing cam height adjustment. 3. **Closed Contained Powder Loading:** Pneumatic vacuum powder transfer systems conveying granules directly from intermediate bulk containers (IBCs) into the tablet press feed hoppers. --- ## Quantitative Results Achieved | Performance Metric | Baseline (Legacy Press) | Post-Upgrade (RTP-35 Lines) | Improvement | |---|---|---|---| | **Shift Output (8 Hours)** | 1.20 Million Tablets | 1.71 Million Tablets | **+ 42.5%** | | **Tablet Weight RSD** | 3.2% | **1.08%** | **66% Variance Reduction** | | **Capping / Defect Rejections** | 1.8% of batch | **< 0.05%** | **97% Defect Reduction** | | **Cleanroom Tooling Changeover** | 120 minutes | **45 minutes** | **62% Faster Turnaround** | --- ## Client Testimonial > "The commissioning team from GentlemanPharmed executed our SAT and IQ/OQ protocols in under five days. The RTP-35 machines have been running two consecutive shifts daily with zero unpredicted downtime over the past 14 months." > — **Engr. Tariqul Islam**, *VP Manufacturing Operations, BD Pharmaceuticals*