Investigation of Serrated Roll Surface Differences on Ribbon Thickness During Roller Compaction

Abstract

Many parameters are considered when developing a roller compaction process. However, roll serration volume is generally not considered when using serrated rolls. It was hypothesized that serration volume of concavo-convex rolls can have a significant effect on ribbon thickness due to differences in nip angle. Experiments were conducted to investigate ribbon thickness using different roll sets having a range of serration volumes. Roll sets with approximately twice the serration volume produce ribbons 20-25% greater in thickness. These results correlated with physical measurements taken of the serrations from each set. Thus, differences in roll serration volume can significantly affect ribbon thickness.

Quality-by-Design III: Application of Near-Infrared Spectroscopy to Monitor Roller Compaction In-process and Product Quality Attributes of Immediate Release Tablets

“…For PCA, preprocessing included NM, SG, 2D, and auto-scaling. As described earlier, batches 1-14 was each compressed at three different compression force (8,12, and 16) kN force leading to a total of 42 different lots. Three tablets from each lot (42×3=126) were used for model development.…”

“…Higher RP on the other hand was found to increases the density of the ribbon and in turn produces tablets with higher crushing force (CF) and low friability (6,7). Roller surfaces (smooth vs knurled) were shown to influence the bulk and tapped densities of the granules (8).…”

“…Two binder types, hydroxypropyl cellulose (Klucel® EXF and Nisso®-L) and two lubricant types, magnesium stearate (MgSt-M and MgSt-D) are the formulation variables evaluated. Three RPs (20,80, and 140 bar) and three compression force (8,12, and 16 kN) were studied as processing parameters. In addition, binder and disintegrant levels were evaluated leading to total of 42 different lots.…”

Application of Near-Infrared Spectroscopy in Real-Time Monitoring of Product Attributes of Ribbed Roller Compacted Flakes

“…Raw material properties, such as particle size and morphology as well as process variables (feed screw speed, roll speed (RS), roll force (RF), roll gap, and roll surface), had been shown to affect the characteristics of the flakes which eventually affected the granules size distribution, flow characteristics, content uniformity, and compressibility after milling (3,7,8). The two main characteristics or critical quality attributes (CQA) of the flakes which are likely to affect the granule characteristics are density and strength.…”

“…Smooth rolls are less suitable due to poorer material gripping capability. The roller compaction process has considerable advantages, including ease for continuous processing, consistent production, time scalability, and less unit operations, and therefore, has the potential to reduce manufacturing costs (3).…”