Segments: Next-Generation Tablet Press Technology

By Todd Martin, Sr. technical service engineer, Natoli Engineering

The expiration of Fette’s patents on die table segments has opened the door for other press manufacturers, such as KORSCH and Romaco (Kilian), to introduce segment turret presses. Tablet tooling suppliers are also expanding into this field, making segments one of the fastest-growing technologies in solid dose manufacturing.

What are segments?

Segments replace a conventional rotary press’s die table, dies, and die-lock screws with a single set of precision-engineered parts—typically three segments for single-sided presses or five for double-sided. Each segment locks into place with bolts and wedges, allowing fast setup and greater tooling density.

Benefits

Segments boost productivity by increasing output 20–25% and reducing setup time by up to 88%. Their superior flatness (≤0.010mm, vs. ≤0.050mm for conventional dies) improves product yield and reduces powder loss. They also eliminate risks of loose or rotated dies. Segments are compatible with advanced options like multi-tip tooling, tapering for easier ejection, and “heel-to-toe” orientation for extended life.

Drawbacks & Challenges

Despite their advantages, segments cost more and have longer lead times. They are less flexible for R&D, where small-batch runs often require only a few tooling stations. Manufacturing segments demands extreme precision—tight bore angle tolerances and set grinding—to ensure performance. Accurate OEM specifications and supplier expertise are critical to avoid costly errors.

Materials

Segments are commonly produced from high-performance steels like Sleipner for durability, Bohler’s M390 stainless steel for corrosion resistance, or carbide inserts for highly abrasive formulations.

Adoption & Outlook

With retrofit turrets available, manufacturers can adopt segments without purchasing new presses. As precision improves efficiency and yields, segments are rapidly becoming an industry standard. Yet, understanding their costs, complexities, and supplier quality remains essential for successful integration.