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Scaling Tableting Processes from Compaction Simulator to Rotary Presses-Mind the Sub-Processes.

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Summary

Compaction simulators offer valuable insights for tablet development, accurately mimicking rotary press processes. This study presents methods to enhance simulation precision for materials and feeding, improving process transfer.

Keywords:
compaction simulationlubricationpowder blendsscaling of tableting processesshear number

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Area of Science:

  • Pharmaceutical Sciences
  • Materials Engineering

Background:

  • Compaction simulators are crucial tools in tablet formulation and process development.
  • Their ability to replicate rotary press compaction and sub-processes like feeding and filling requires systematic evaluation.

Purpose of the Study:

  • To evaluate the precision of compaction simulators in mimicking rotary press compaction.
  • To assess the influence of material properties and feeding on tablet tensile strength and simulation accuracy.
  • To develop strategies for improving process parameter scaling between simulators and rotary presses.

Main Methods:

  • Investigated the effect of material deformation behavior, blend composition, and feeding on tensile strength.
  • Compared simulation precision with rotary presses of varying scales.
  • Analyzed compaction stress over time profiles and adapted a shear number approach.

Main Results:

  • Compaction simulators demonstrated good overall simulation performance.
  • Visco-plastic materials showed compaction profile-sensitivity.
  • Lubricated blends of ductile particles exhibited shear-sensitivity during feeding.
  • Strategies for compensating these sensitivities were developed.

Conclusions:

  • Compaction simulators can effectively mimic rotary press compaction with appropriate adjustments.
  • Developed methods enhance the determination of scaling parameters for reliable process transfer.
  • The study facilitates quicker and more dependable process development in tablet manufacturing.