CRITICAL DIMENSIONS

THE IMPORTANCE OF
PUNCH LENGTH
& CUP DEPTH
WHITEPAPER

NATOLI ENGINEERING COMPANY

 HEAD HEAD FLAT

WHAT ARE THE

NECK
MOST IMPORTANT
DIMENSIONS
OF MY TABLET
COMPRESSION
TOOLING? BARREL

KEY
WORKING LENGTH
& CUP DEPTH

TIP
(TO FULL TIP
BARREL) LENGTH

TIP DIAMETER

CUP DEPTH

TIP WIDTH

OVERALL
LENGTH

Manufacturing tablets to a uniform hardness,

weight, and thickness requires tablet WORKING
press punches of consistent length. This LENGTH
whitepaper describes how to understand
punch length, measure it correctly, and
how wear affects tooling length and tablet
consistency. This paper will also address
the importance of specifying cup-depth
tolerances, and establishing a punch
inspection and maintenance program to
verify that all punch lengths and cups are
within dimensional tolerances.
These two measurements are the most
critical to evaluate through the life of your
tablet compression tooling.
IDENTIFY
WORKING AND
ACCURATELY MEASURE
LENGTH
THE WORKING LENGTH
Punches are engineered and manufactured to consistent Working length is critical to consistent overall tablet
lengths. The working length of a punch is measured as hardness, weight, and thickness; it should be considered
the distance from the head flat to the lowest measurable the most important dimension in a tool inspection
area of the punch cup. program. If the working length varies within a set of tools,
Specific high and low working length tolerances are then those tablet characteristics will also vary. Working
established during the tooling design process to ensure length consistency is the key. As in-process tooling begins
the tool manufacturer produces new punches within the to wear, resetting the range of working length becomes
appropriate working length range. The distance from the necessary. The working length of punches is engineered
head flat to punch tip is the overall length of the tooling. to a standard range of 0.051mm (0.002 inch). This means
The punch tip comprises the cup and the land (Figure 1). that, within a set of punches, the difference between the
working lengths of the longest and shortest punch is no
more than 0.051mm (0.002 inch).

IMPORTANT REMINDERS
»» Periodically inspect punches to ensure
working lengths do not exceed that tolerance
(or the range your company specifies).

»» When inspecting to confirm a uniform working

length, inspect the upper punches independent
of the lower punches.
FIGURE 1
NATOLI ENGINEERING COMPANY | 636.926.8900 | www.natoli.com
 CALCULATING THE
WORKING LENGTH

It is also critical to measure correctly. Do not calculate

the working length by subtracting the cup depth from
the overall length, as that method can produce results
showing some tools are out of specification when in fact
they are not. The working length of the punches should
be measured for deviation from punch to punch rather
than from a calculated number. Working length can be
measured using a simple digital indicator mounted on
a steel post and stable base, or a more elaborate laser
inspection system.

An important advantage of a laser inspection system

is non-contact lasers eliminate the risk of punch-tip
damage from the sharp tip of the digital indicator. Other
advantages include that critical punch dimensions are
measured simultaneously and can be recorded real-time
into a tool management software database, saving tablet
manufacturers significant time. Whatever equipment
used, measuring the working length of punches that have
embossing or a bisect at the lowest area of the punch
cup is more complicated. In those cases, it is important
to measure from the deepest accessible area of the cup
with the tip of the indicator (Figure 2). Once the lowest FIGURE 2

area of the cup is identified, the technician must be sure to

measure consistently from that point when checking the
entire set.

Reputable tooling manufacturers can provide a working-

length matching report when they deliver a new set of
punches. The matching report pairs each upper punch
with a lower punch, from longest to shortest, and numbers
them accordingly. Matched punch sets minimize deviation
in tablet hardness and thickness, and a matching report
offers helpful guidance during press setup. The length
of the lower punch is more critical than that of the upper
punch because the lower punch largely determines how
uniformly product (granulation) fills and doses in the die.
Product flow characteristics and lower punch binding also
strongly influence the uniformity of die filling. Deviations
in the amount of product allowed into the die affect tablet
hardness and weight.
EVALUATING CUP DEPTH
The cup depth is the distance from the tip edge of the
punch to the lowest theoretical point of the cup. Some
cup configurations have a varying depth, such as those
used to manufacture tablets with scalloped edges. The
cup determines the configuration and appearance of the
tablet faces.
The area between the two tablet faces created by the
die is called the tablet sidewall (Figure 3), sometimes
referred to as the tablet gate or the tablet band. Although
the sidewall is generally not inspected or measured, it is
critical to tablet appearance and manufacturing. Ideally,
the sidewall width will be well-proportioned with the
overall tablet thickness. A tablet with an excessively
thick sidewall appears to be larger overall, creating
the perception that the tablet will be uncomfortable to
swallow. An excessively thick sidewall also requires the
tablet press to exert greater force to eject the tablet from
the die. FIGURE 3

The width of the sidewall depends on the tablet hardness,

weight, and thickness in relation to the cup depth. As the
punch tip wears, cup depth decreases and sidewall thickness
increases. Thus, when comparing two tablets—made from a
shallow-cup punch and a deep-cup punch—the shallow-cup
punch has a thicker sidewall. However, the shallow-cup tablet
will be measurably thinner overall than the deep-cup tablet. Its
wider sidewall makes it visually undesirable and unfavorable
for manufacturing. The wide sidewall of a shallow-cup tablet
also can cause difficulties during film coating because the
tablet may erode at the sharp corner where the shallow-cup
radius and the vertical sidewall meet (Figure 4).

FIGURE 4

NATOLI ENGINEERING COMPANY | 636.926.8900 | www.natoli.com

WHAT ABOUT THE OVERALL
LENGTH OF THE PUNCH?

The overall length is the least important length

dimension of the punch. It is the distance from the
punch tip to the head flat. The overall length is a
reference dimension that comprises two or more
critical dimensions: the working length and the cup
depth. Since both working length and cup depth are
manufactured to a specific tolerance, there is no need
to assign a tolerance to the overall length.
As long as the working length and the cup depth are
confirmed to be within the acceptable range, then
the overall length will be consistent and inspection
is unnecessary. However, the overall length of the
lower punch is somewhat critical when it comes to
setting the punch height for uniform tablet take-
off, which is important to minimize the potential for
tablet damage. If your company’s standard operating
procedures require inspection of the overall length,
the same equipment can be used to inspect the
working length and cup depth. Of course, a tolerance
range and a pass-fail policy must be established.
A WORD ABOUT PUNCH WEAR
With normal use, punches show the most wear at their
tips, which reduces the cup depth. As a result, tip wear also
reduces the overall length of the punch, but does not affect
the critical working length. Any wear of the head flat (not as
common as punch-tip wear) will further reduce the overall
length, as well as reduce the working length. Head flat wear
does not affect cup depth.
Normal maintenance of the cup face, tip, and head also can
affect punch length. Polishing the face using fine abrasives,
hard felt bobs, or stiff brushes can alter critical lengths.
Likewise, if using hard felt bobs and/or stiff brushes with
abrasive compounds to remove product adhered to the
face or to remove surface discoloration or pits (typically
the result of compressing abrasive products), eventually
the punch cup will deepen and possibly alter the critical
working length.
Wear also can occur at the land, which is the narrow flat
area located at the perimeter of the punch tip. The land is
subject to abrasion during compression and is commonly
the first area of the punch to wear. When the land wears, the
tip edge becomes very thin, even razor sharp, which can
result in a condition referred to as J-hook (Figure 6).

J-hook normally occurs on the upper punch tip and

is a common cause of tablet capping and lamination.
Polishing the punch using a soft, unsewn cotton buff
wheel and polishing compound can remove J-hook
and restore land. While polishing and restoring the
land will prolong the useful life of your punches, it will
eventually reduce the cup depth and overall length as
these are elements of controlled wear.
Uniform tool length is critical for maintaining tablet
consistency and smooth press operations. The most
important dimension of the punch as it relates to tablet
quality is the working length, followed by the cup depth,
and then the overall length. To achieve the highest
level of tablet uniformity, reputable manufacturers of
tablet compression tooling provide a working-length
matching report. Setting up the tablet press in the
sequence of the supplier’s matching report will provide
the best scenario for tablet consistency.

QUALITY TABLETS COME

FROM QUALITY PUNCHES.
Natoli Engineering Company is the world-renowned
leader in tablet compression tooling. Founded on
the uncompromising principle to manufacture and
deliver the highest quality products at a fair price
with exception customer service, Natoli continues
to build on over 45 years of innovation and industry
leadership.