Roller compaction granulation, a continuous dry granulation process, was used to produce granules. Others prefer to spraydry liquid suspensions into granules. Table 1 lists some advantages and disadvantages of roller compaction compared to wet granulation. Roller compactors pci oe schweikert 0614 printed in germany the alpine technologies machines and complete plants for compaction briquetting granulation size reduction pelletizing extrusion spheronization hosokawa alpine compaction is a member of the hosokawa micron group, responding to global needs through emphasis on materials science and. This process avoids the requirement for additional binders or liquids, which are necessary in the wet granulation process, and as a consequence of the wetting process a drying phase is also required. A feeding system, which converts the powder to the compaction area between the rolls.
Roller compaction for tablet dosage form development. Sep 04, 20 typical properties of conventionally placed concrete. In this work, we demonstrate how online process control can be applied on roller compaction using the simulator built in part i of this paper. Sep 01, 2016 roller compaction is a process typically used in the pharmaceutical and food industry to increase the flowability of a powder by forming granules of greater size and density. A schematic of the roller compaction process is provided in figure 1. When preparing tablets by roller compaction, managing c ompactability and friability can be challenging due to the double compression process. Roller compaction accepted in revised form 20 april 2009 process parameters and their impact on the critical quality attributes of the.
Roller compaction is principal step in dry granulation, an exploiting agglomeration. Apr 15, 2010 roller compaction is the major process of dry granulation which is attractive to heat or moisturesensitive pharmaceutical products. The terms rollcrete and rolled concrete are no longer to be used. Scaleup of a pharmaceutical roller compaction process. The working principle of pharmaceutical roller compactor. Equipped with amplitude and frequency controls specifically designed to compact acp capable of at least 2000 vibrations per minute have a gross static weight the same as. Types of compaction there are four types of compaction effort on soil or asphalt. But the most straight forward granulation method uses a roller com pactor and no. Vibration impact kneading pressure soil compaction soil compaction is defined as the method of mechanically increasing the density of soil. A practical approach for the scaleup of roller compaction. Roller compaction design and critical parameters in drug. Roller compaction study page 1 of 4 freemantechnology the influence of roller compactor process parameters on granule properties. In a roller compaction process, a powder blend containing active pharmaceutical ingredient api and excipients passes through two counterrotating rolls that compact the. Apr 16, 2017 a roller compactor generally consists of three major units.
The balance of forces during the compaction process can be represented by a differential equation of. Roller compaction densifies the powder or particle which can adversely affects the dissolution of product. Multivariate synergies in pharmaceutical roll compaction diva. This is a pdf file of an unedited manuscript that has been accepted for publication. Continuous dry granulation by roller compaction 3 1 background on continuous dry granulation by roller compaction 1. Unlike wet granulation processes, which require liquid binders, alcohol solvents and high temperature drying, our roller compaction is free of these additional ingredients and energy requirements. Roll compaction of pharmaceutical excipients and prediction using. During roller compaction the dry powders of the active ingredients and excipients are blended in a blender and further roller compacted and milled to form granules.
Ribbons were created with the roller compactor brc 25 from bohle. In construction, this is a significant part of the building process. Modelbased approach to the design of pharmaceutical roller. Oct 15, 2020 therefore, dry granulation and roller compaction in particular may be the best option for these formulations. This process is achieved by feeding powder through a set of directly opposed, counterrotating rollers. A constrained optimization is then formulated to invert the jypls model to find the key process settings of the fitzpatrick ir520 to make the same quality of ribbon using the same raw materials formulation as the. Roll compaction is a continuous process commonly used in the pharmaceutical industry for dry granulation of moisture and heat sensitive powder blends. The roller compaction process alexanderwerk youtube. In addition to standard measurements of roll speed, feed screw speed, hydraulic pressure and roll gap, our novel instrumentation of the roll itself makes it possible to measure normal stress across the roll surface.
In recent years, dry granulation using roll compaction dgrc attracts considerable interest of engineers and researchers, especially in the pharmaceutical. Good quality granules can be obtained by optimizing roller compaction process parameter such as compression force, roller speed, screw feeder speed, roll gap. It expresses the correlation between the ground contact force and the indentation of the roller drum. Pdf systematical approach of formulation and process. Roll compaction is an agglomeration process in which powder is densified by passing through two. Finally these flakes are then reduced in size to the desired grain size. In contrast to the wet granulation process, compaction granulation requires neither drying nor the addition of binders. During the process the powder is fed by gravity or with the help of screw drivers into two rotating rolls. They act as ball bearings to reduce the friction among particles. Roller compaction is a dry granulation process device procedure in which the powders containing active ingredients and excipients are agglomerated between.
The process avoids the use of liquids and high temperatures. Roller compaction of anhydrous lactose and microcrystalline cellulose fitzpatrick chilsonator studies. Glidant is added to a great number of roller compaction formulations to improve the flowability of precompression powder. Roller compaction is one of the steps for dry granulation of pharmaceutical powders. May 07, 2018 continuous dry granulation by roller compaction 3 1 background on continuous dry granulation by roller compaction 1. The term roller compaction is also defined by aci as a process for compacting concrete using a roller, often a vibrating roller. The various process parameters involved in roller compaction process and its interrelation are given in figure. Roller compaction of anhydrous lactose and microcrystalline. Roller compaction is a continuous dry granulation method that relies on particle bonding. In detail at the beginning of the process the powdery and fine crystalline materials are fed into the.
Introductionthe design and development of a solid dosage form depends on the characteristics of active pharmaceutical ingredient s api and excipients. Using various contact widths, the research team simulated the effect of the wheel load moving during compaction processes. The tablet is the most preferred dosage form and pharmaceutical industry uses different processing techniques wet granulation, dry granulation and direct compression to modify the characteristics of raw particlespowder in order. Equipped with amplitude and frequency controls specifically designed to compact acp capable of at least 2000 vibrations per minute have a gross static weight the same as static steel wheeled. The principle of dry granulation here is quite different and guarantees high efficiency. The evib value is a physical measured value that correlates directly with the plateloading test used in earthworks and road construction. Continuous dry granulation by roller compaction is a wellestablished process in pharma ceutical, chemical and life science industry. Roller compaction rc is a continuous process for solid dosage form manufacturing within the pharmaceutical industry achieving similar goals as wet granulation while avoiding liquid exposure. Modelbased approach to the design of pharmaceutical.
The effect of roller compaction and tableting stresses on. Dry granulation is an agglomeration process used to produce. Modeling and control of roller compaction for pharmaceutical. Basically, the idea behind dry granulation is that a fine powder that is subjected to a predetermined amount of force that transforms it into a compact sheet or solid. The compaction and granulation of chemical materials is an important part of the chemical industry. Binders are critical functional ingredients in tablets prepared by roller compaction. The process the roller compactor forces fine powders between two counter rotating rolls and presses the raw material into a solid compact or sheet, so called flakes. This process is also energy efficient and suitable for processing pharmaceutical agents that are sensitive to moisture and heat. Roller compaction and process scale up marlene cardin 20191024t11.
The granules were then compacted using varying tableting. The influence of roller compaction processing variables on. The jypls model relates api mass fraction, excipient mass factions, and roller compaction process measurements to ribbon properties. Aug 01, 2016 a roller compactor generally consists of three major units. Koppern not only manufactures roller presses but also provides complete fertilizer production plants.
Advances in roller compaction drygranulation research. Roller compaction operations roller compaction is a continuous dry granulation process to increase the bulk density and uniformity of powders into free flowing granules used in downstream manufacturing operations. A hardening soil model was implemented to simulate the compaction process using volumetric. Mechanistic study of the effect of roller compaction and lubricant.
Khinast, modelbased approach to the design of pharmaceutical rollercompaction processes, international journal of pharmaceutics. Most products are first produced at small scale, such as lab or pilot scale. During the process the powder is fed by gravity or with the. In the pharmaceutical industry it assists in binding tablet ingredients together to form a larger mass. The powder to be compacted must be compressible or have to add compressible excipients or additives to the formulation. In pharmaceutical applications the most common target is to increase the flowability of a powderor powder blend to enable the fast and homogeneous filling of a tablet press. Bomag compaction measurement and documentation systems. Dry roller compaction is the best granulation process for materials sensitive to moisture and heat. Qbd solid fraction analysis in roller compaction operations. To develop a roller compaction method for preparing carbomercontaining controlledrelease tablets comprising watersoluble or waterinsoluble model drugs theophylline or ketoprofen, and to demonstrate the utility of carbomer in creating controlledrelease formulations via the roller compaction process. Currently, the product quality of roller compaction is analyzed offline in the quality control lab. The compaction process is a function of compactor s weight, soil type and contact width of the wheel loading. Pdf roller compaction is one of the steps for dry granulation of pharmaceutical powders. Subsequently scaling up to full scale production can be time consuming, frustrating and costly.
Technical information a member of the jrs group excipients. The compaction behaviour of powders in roller compaction process is influencing by. So far, it has replaced the slugging granulation process in most material processing setups. Roller compactor simulation a continuum model can be used to determine the stress distribution on the rolls as a function of material properties and process parameters 1.
From a quality by design perspective, the aim of the present study was to demonstrate the applicability of statistical design of experiments doe and multivariate modeling principles to identify the. It is a complex procedure due to the diversity of available powder blends and the control and adjustment parameters involved in the. Roller compaction is a unit operation in dry granulation process in which the powders containing active ingredients and excipients are agglomerated between the rollers of compactor. Effect of rollcompaction and milling conditions on granules and. For the purpose of this process, you need a roller compaction machine. Plus, cleanup is easier, especially since most roller compactors disassemble into easytohandle components that you can place into a washing machine. Design space estimation of the roller compaction process. Granulation using roller compaction is commonly known as dry compaction. One major field for the application of roller presses compactors is the fertilizer industry. Pdf this study is part of an ongoing project to enable the full specification of the design space for roller compactor systems and shows how the. Dec 12, 2018 roller compaction is a method of powder compaction of dry powders into a solid mass known as the ribbon. Ammann took the first steps toward providing these processes in 1998 with the advent of ammann compaction expert ace, an automated compaction measurement and control system.
Processing powder blends can present a number of challenges. Results of the study revealed that ratio between screw feeder speed and roller spe effect on the compressibility and screw feeder played a pivotal role of predensification during roll compaction process 47. Oscillatory rollers can be effective for both intermediate and finish rolling applications oxidation of asphalt binders is more rapid if high density was not achieved during the compaction process avc too high potholes result from weakness in bases or subgrades rather than from improper rolling compaction of flexible pavements. Pdf overview on roll compactiondry granulation process. Technologies and their applications in drug delivery and development. The influence of roller compaction processing variables on the. In pharmaceutical applications the most common target is to. Pdf study of dry granulationroll compaction process using. Pdf study of dry granulationroll compaction process. Roller compaction is a popular dry granulation technology. We provide equipment and services for a variety of industries. How pharmaceutical roller compactor machines work the working principle of roller compactor machine is simple. Understanding the compaction process helps roller operators be more effective and efficient vibratory rollers are typically the best choice for breakdown rolling applications warm mix asphalt is a rapidly growing mix type which is easiertocompact on most applications. Good quality granules can be obtained byoptimizing roller compaction.
The flowability of the roller compacted substances was determined either with the schulze shear cell ff12c value or using the hausner ratio graph 2. Although, dry granulation has been used in pharmaceutical. This is because it increases the capability to store and. Evaluation of different binders for roller compaction. Dry granulation is a method where no moisture and heat is used to process powders into granules. Pdf the influence of roller compaction processing variables on.
The option to use a dry granulation process, based around a roller compactor and integral millscreen, has significantbenefits not only in terms of processing cost. Basically, the idea behind dry granulation is that a fine powder that is subjected to a predetermined amount of force that transforms it. To obtain flow index ffc values indicating good flow, a minimum of 25 kn compaction force during roller compaction was needed. During roller compaction, a blend of the api and intragranular excipients is passed between two counterrotating rollers to generate ribbons. Compaction gets even smarter precise, transparent and verifiable compaction processes increasingly are required on construction sites. Scaleup of a pharmaceutical roller compaction process using.
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