Roll Compactor Working and Application in the Pharmaceutical Industry!
Riddhi Pharma Machinery 
Dry granulation is a crucial process used in the pharmaceutical sector. The process is carried out with the help of a roll compactor, also known as a dry granulator. The Roll Compactor machine is used in the pharmaceutical, food, and chemical industries to improve bulk density, create granules, process pharmaceutical ingredients dustlessly, and reduce particle size. Compactors use two counter-rotating rollers to crush fine powders into solid particles such as flakes, strips, or sheets. The solid particles are then crushed into granules.
Two methods are there to complete dry granulation in the pharma industry. The first method is slugging and the second one is roll compaction. Slugging was employed from 1950 to 1970, but roller compactors are currently the dominant equipment because they offer great output.
If you are considering buying a roller compactor machine for use in pharmaceutical production, read our informative article. In this post, we will discuss the working principle, advantages, and uses of this dry granulator.
What is Roller Compaction?
Roller compaction is a form of powder compaction that converts dry powders into a solid mass known as ribbon. This technique involves passing powder through a series of directly opposed, counter-rotating rollers under extremely high pressure. The procedure does not need the use of liquids or high temperatures. As the volume shrinks in the region of greatest pressure, the substance solidifies into a compact sheet or flakes of ingredients. These flakes or compact sheets of materials are shrunk in size to achieve the appropriate grain size. Finally, using an oscillating granulator machine, a multimill machine, a continuous mill, or a sizing machine, these chips or flakes are reduced to the necessary size granules or grains.
The sieve size should be carefully chosen to avoid the formation of particles. The chosen sieve determines the size of the resultant granules or grains. Dry granulation is used to improve the bulk density of powders and particle size, resulting in a better flow of scattered material; this is an essential aspect in the fabrication of tablets and capsules employing production equipment.
The most significant factors in the dry granulation process are powder feeding, compaction pressure, and gap diameters. The powder is fed into the rollers, and depending on the feed rate, gap diameter, and force, the powder is 'compacted' into a predetermined ribbon thickness. Precise process control is required to achieve homogenous granule characteristics. This is governed by the pressure with which the powder is driven through the rollers.
The Working Principle of a roll compactor:
A roller compactor typically consists of three primary elements.
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A feeding mechanism that transfers powder to the compaction region between the rollers.
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A compaction unit in which powder is compressed between two counter rotating wheels to form a ribbon using force.
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A size reduction equipment for milling ribbons into the required particle size.
The most essential parameter in dry granulation is the force imparted to the powder crushed between two rolls. The applied force is represented in kN/cm, which stands for force per centimeter of roll width.
How does the roll compactor machine work?
The powdered and fine crystalline materials are put into the compactor's hopper at the beginning of the procedure. An incorporated screw feeder with stirrer guarantees an equal flow of material. The screw's construction allows it to pre-compact and de-aerate the raw material. The vertical screw feeder drives the items into the roll compactor's nip region.
The vertical feed screw delivers powder to the compacting rollers via the pre-compacting chamber and compacting zone. The powder is then gently pushed between the compacting roller gaps. The hard chips or flakes are subsequently ground into a fine powder using an adjustable-speed AC Variable Frequency Drive (AC VFD).
The adjustable screw speed has a direct influence on the roller gap and, as a result, the roll compactor's compaction capabilities. The roller compactor equipment from here crushes the material into granules. The adjustable roll velocity determines the product's retention time within the compaction zone. The hydraulic system transfers the appropriate compaction force to the rollers. The hydraulic unit maintains the set roll force constant, resulting in a uniform flake, while scrapers keep the rolls neat and tidy.
Following compaction, the flake falls into one or more motor solvent extraction mills. To avoid penalties, incoming chips are reduced to the nearest size practicable. The sieve used determines the ultimate grain size of the granule. An integrated testing equipment can be used to separate the particles from the primary substance.
Conclusion
If you need a high-quality roll compactor, Ridhi Pharma Machinery Ltd is a reputed brand you can rely on. We have years of experience in manufacturing pharmaceutical machinery. And, we offer roll compactors that are easy to operate and maintain. If you need further assistance with a dry granulator, contact us now.
Frequently Asked Questions
What is the main use of a roll compactor?
It is mainly used for dry granulation of powders, particularly in pharmaceutical manufacturing. The machine is useful for better powder flow and compressibility for making tablets or capsules.
Why choose dry granulation over wet granulation?
Dry granulation is chosen when the product is sensitive to water or heat, or when a cleaner, solvent-free process is needed.
What makes the granules from a roll compactor special?
They are uniform, dust-free, and flow well, which makes subsequent manufacturing steps (like tablet pressing) more efficient and reliable.
How do you adjust the size of granules?
By changing the roller gap, compaction force, and the size of the screen in the milling unit, the size and density of granules can be controlled.
