Production

Roll Compactor

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Roll Compactor

Operation

GranMech Roll Compactor is the ideal roller compaction system for dry granulation of pharmaceutical
powders. Our pharmaceutical roll compactor provides optimized granulated material to improve
downstream powder flow characteristics and subsequent maximized tableting efficiencies, achieved via
a unique pre-compression feed system and precision real-time roll gap control. The roller compactor
machine is fully contained, wash-in-place capable and scalable from lab to production.
GMRC provides instantaneous, continuous compacting of pharmaceutical fine powders into densified
sticks or corrugated sheets that can be precision granulated to desired mesh size. The tightly sealed
design improves product quality by controlling density and particle size, increasing processing
efficiency by eliminating dust problems and caking, as well as reducing shipping, handling, packaging
and storage costs. Minimizes pharmaceutical roll compactor maintenance and production downtime:
Fewer parts and easy access for tear down and cleaning allow faster changeovers and simplified parts
inventory. Achieve full containment with minimum initial investment — a significant benefit for
pharmaceutical R&D and production scale-up.

Roller compactors for the pharmaceutical industry

Compaction and granulation in the pharmaceutical industry
Three-quarters of pharmaceutical formulations are administered in solid form such as tablets or capsules. Beside the active ingredients the different recipes include a wide range of different excipients and additives (fillers and flavoring). Because of the different raw material properties, the fine powder mixtures cannot be pressed directly to finished drugs in a tablet press. Instead, it is necessary to compact and granulate the powder in advance With both processes the physical properties (granule size, granule particle distribution, bulk density, granule hardness and active surface) can be influenced so that the powder can be processed to the final product very accurately and economically. Compared with powder, granules are characterized by a greatly improved flowability and higher density (volume reduction).

This provides the following advantages:
• accurate and precise dosage
• reduction of health hazards by reduction in dust formation at the workplace
• increase of machine life time through reduction of dust formation
• possible positive influence to the dispersion and solubility characteristics
• homogenous distribution

Applications
For many years pharmaceutical companies as well as specialized providers all over the world have been
using solutions to produce tablets, capsules, life science products, flavours, instant powders, intense sweeteners and many more. Lactose Sodium bicarbonate Riboflavin Antibiotic

The processing principle of roller compaction and granulation is relatively straight forward. However, only the use of modern production technology in connection with highly-developed feeding and control technology enables an accurate and economic production of high quality roller compacted and granulated products, which meet pharmaceutical requirements.
Granulation using roller compaction is commonly known as dry compaction. 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. Since no wetting takes place in roller compaction the product is not subject to chemical reactions or high temperature drying. In addition the benefit of reduced environmental impact is achieved by dry compaction. The compaction of the materials is realized by high mechanical pressing forces, which provide the production of a compressed ribbon.
The high quality of the final product is determined by the compaction process and is achieved in three consecutive steps:

1. Feeding
Using a suitable feed-in system, the raw material (powder) is routed through a horizontal screw
feeding section. This has the function to provide the product precisely dosed, constantly and accurately to the rollers.
2. Compaction
The powder is compacted between two rollers to a homogenous solid flake, whose bulk density is signifi–
cantly higher than the bulk density of the bulk material. The air, which is displaced during compaction, must be allowed to leave the process properly.
3. Granulation
The flakes, which were produced through the compaction process, are granulated using a suitable
single or multistage granulation system. In this way,granules are created to the defined granule size required.
Type of  roller compactors for the pharmaceutical industry:
Roller compactor BT 120 Pharma
Roller compactor WP 120 Pharma
Roller compactor WP 150 Pharma
Roller compactor WP 200 Pharma