Are you doing some dry granulation – whether R& D or large scale?

Well, it doesn’t matter what scale you are doing it.

What matters; you may need a roll compactor machine to help you out.

For those that are unfamiliar with this;

I am going to walk you through every aspect of roller compactor machine for dry granulation.

I’ll take you through the basic parts, specifications, working principle and designs of roller compactor machines, just to mention a few.

As a bonus;

I’ll recommend a series of roller compactor machines you can choose for your dry granulation needs.

It’s something you cannot just miss.

Chapter 1: What is a Roll Compactor Machine?

A roll compactor also known as a chilsonator is a device that converts raw materials into powder.

The machine is also used to transform preprocessed powders into several other forms.

These include flakes, ribbons, and sheets.

Powder for dry granulation

Powder for dry granulation

To get them into their desired final form, the powders may undergo further compaction within the chilsonator.

As you will learn later in this guide, it uses two rollers and a milling system, which are in constant motion. These rollers produce material with:

  • Better flow characteristics
  • Increased density

Of course, this makes these materials suitable for other processes such as tablet compression or capsule filling.

The bottom line:

Roll compactor is a good example of a dry granulator machine.

Over the years, roller compaction technology has become a perfect choice for processing heat and moisture sensitive materials.

And, I can tell you this for free – roller compaction technology produces high quality granules at a lower cost.

Now, let me take you a step further and explain the basic principles behind dry granulation.

Chapter 2: Why you Need Roller Compaction for Dry Granulation?

Well, that’s a pretty good question.

Roller compaction is so far the main and best technique used in dry granulation applications.

This is because it makes economic sense in all angles.

For instance, it ensures maximum productivity even when your resources are limited.

I mean, we all want to use things that not only make our work easier but also that help us achieve maximum efficiency.

Granules

Granules

This is precisely why you need roller compaction for dry granulation.

Read on to find out more reasons why.

2.1. Basic Principle of Dry Granulation

Simply put;

Granulation is the formation of larger particles by joining together smaller ones.

In the pharmaceutical industry, this process usually involves compressing powders together to form granules.

These could be powders of either the same or different chemical compounds.

The product so formed is called a granule, and its comparatively larger size makes it easier to further process.

Before now, wet granulation was the most common technique for granulating materials.

This process made use of liquid binders.

Wet granulation

Wet granulation

Drying was also part of the process to help get rid of the moisture present in the granules after processing.

Starting from the late 1940s however;

A better understanding of active pharmaceutical ingredients resulted in the increased use of dry granulation techniques.

Please note;

Dry granulation eliminates the use of liquid binders and the drying process.

It instead uses high pressure, often 30-70 bar, to force particles to bond together.

Occasionally, a binding agent, a dry powder, may be added to ensure better bonding.

Typical binders include:

  • Microcrystalline cellulose
  • Methyl cellulose
  • Hydroxypropyl cellulose

The process may also incorporate the use of fillers such as lactose and starch, or glidants.

Initially, slugging was the dry granulation process of primary use.

Say what?

Well, slugging; a batch process in which powder is fed into a large compression machine to form slugs.

The slugs are then transferred to a different machine to be set into the appropriate final form.

These could be tablets, capsules, or powders for an oral suspension.

But why did slugging stop?

Or become unpopular?

Well, it is a relatively slow process.

 

It has an average output of 30-50kg/hour.

This is very slow for large-scale granulation.

Besides, the process causes significant sound pollution and demands more space, energy and time to produce its yield.

Slugging, is not interfaced with modern control systems.

This denies operators the chance to tweak the process to enhance product consistency.

The bottom line?

I mean, it’s slow, noisy and quite traditional.

It’s quite apparent that operators would want a better alternative for dry granulation.

One like roll compaction which is the primary technique in use nowadays.

Unlike slugging, in roll compaction powder passes through a gap set between counter-rotating rolls.

Depending on the design, the powder can be delivered to this gap via gravity or use an active process.

Internal section of roll compactor

Internal section of roll compactor

At this gap, the powders are put through increasing pressure, aggregating them into a larger form, such as a flake.

This gap in a roll compactor is divided into three regions: slip, nip, and release.

When the powder is fed into the rollers, it first passes through the slip region.

The particles are rearranged at this point.

But then, given the distance between the rolls, the particles easily slip, as the pressure exerted here is relatively small.

At a variable angle, the nip angle, the powder moves apace with the rolls and is moved into the nip region, where most of the compaction occurs.

As the now compacted powder moves further down the process, the distance between the rolls widens.

This makes the compacted powder to fall into the release region.

From the release region, the powder goes into the milling system, where it is processed into the desired size.

A system of filters then isolates oversized granules and fines to be recycled.

The finished products on the other are collected in a different assembly.

And by the way, I have a comprehensive guide on this process: Dry Granulation: The Definitive Guide.

2.2. Benefits of Roller Compaction Technology for Dry Granulation Process

As I’ve told you earlier, roller compaction is the primary technique in use within the pharmaceutical industry.

But why?

It is significantly superior to other granulation techniques.

End product of roller compaction

End product of roller compaction

      a) Roller compaction is cost effective

First of all roller compaction is cost effective.

It beats other granulation techniques like wet granulation that require extra ingredients, i.e., liquid binders to hold products together.

      b) Roll compactor dry granulation is suitable for moisture and heat sensitive material

Similarly, since it doesn’t require such liquid binders, roller compaction can be used with sensitive chemicals.

These could otherwise be degraded when exposed to the heat and moisture in wet granulation.

Likewise, the absence of a drying process in roller compaction makes it a suitable technique for compounds with low melting points.

      c) Roller compaction is a simple dry granulation process

As a continuous manufacturing process, roller compaction has been demonstrated to be relatively simple and easy to operate.

With the input and several variables easily adjustable, it is far easier to achieve content uniformity using this process.

      d) Roller compaction technology guarantee high production

Roller compaction also enjoys a high mass output, depending on the capacity of the machine in use.

There are small variants of roll compactors that may process only hundreds of grams of product every hour.

Industrial-sized roll compactors can, however, churn out more than 5 tons per hour.

That said, roll compaction isn’t a perfect process, and suffers two main disadvantages.

      a) Tablets show loss of re-workability

One, tablets made by roll compaction suffer from a loss of re-workability.

This somewhat demonstrates a lower tensile strength when compared to tablets produced via other processes, i.e., direct compaction or wet granulation.

This phenomenon as most resources explain is a consequence of double compaction, first due to the initial roll compaction and then during tableting.

       b) It produces more “fines”

The process also generates quite a bit of compact powders, called fines.

The usage of a liquid binder in wet granulation essentially eliminates this issue.

However, we know that roll compaction makes no use of such liquid binders.

As such, recycling is necessary for this process to help maintain a decent fines yield.

Having said that, let’s “disassemble” this machine to see its main parts and components.

Chapter 3: Main Parts of Roller Compactor Machine

As you can see, a roller compactor machine for dry granulation is made of a range of parts and components.

For a fact, I cannot explore all of them here.

It’s for that reason, I will focus on the main parts and components only.

But first I want you to have a quick overview of the image below:

Part of a Roller Compactor

Of course, these are what we have in here:

Roll compactor machine

Roller compactor for dry granulation

Again, I want you to watch the video below so that you can see these parts and components clearly.

It is a 4 minute video, showing assembly and disassembly of roller compactor machine.

In this article, I am going to focus on the following parts of a roller compactor machine:

  • Feeding system
  • Compaction system
  • Flake crusher
  • Operator console
  • Drive system

So in this section, I am going to focus on these main parts of the roller compaction machine for dry granulation and other related components.

Also, I want to mention here that not all roller compactor machines are the same, especially when it comes to design.

However, the working principle is still the same.

The various parts may have different configuration, but still achieve one goal – dry granulation.

Therefore, in case any part malfunctions, the machine will not work properly.

So here are the five most important parts of a roller compactor machine;

3.1. Raw Material Feeding Unit

The material feeding unit is the part that you put in material for processing.

Quite a number of raw material feeding units take the shape of a cone.

material feeding unit

Material feeding unit

This makes it easier for material to move seamlessly into the machine.

3.2. Material Feeding System

Don’t confuse this with the feeding unit.

The feeding system is located inside the machine and not on the outside like the feeding unit.

This is the part that consistently and uniformly delivers material between the two pressure rollers in the machine.

We will learn more about the rollers in section 3.3 below.

So as I was saying, the feeding system does more than delivering the raw material onto the compaction system.

It also helps to remove trapped air from the materials before releasing them into the pressure rollers.

There are different feeding systems, but most machines today use the screw feeding mechanism.

Please note;

The feeding system is quite critical in the functionality of a roll compactor machine.

It is the part of the machine that determines its output capacity.

Feeding system

Feeding system

With this in mind, note that you can opt for either a twin or single pre-compression feeding system.

These two feeding system designs can enable you to perform dry granulation even when dealing with low bulk density materials.

The bottom line?

As you buy a roll compactor machine, choose one that has the appropriate feeding system for your type of application.

3.3. Roller Compaction System

This is the central and most important part of the roll compactor machine.

It is the part responsible for compressing the material into the desired form, i.e., flakes, ribbons, and sheets.

So, when the material comes through from the feeding system, it goes here where it is compressed uniformly into the above forms.

Like I said in section 3.2, the feeding system delivers material into the rollers of this machine for compaction.

Following a variable set speed, the feed system forces the pre-compressed powder into the two rollers here.

 

Roller compaction system

Roller compaction system

Now, regardless of the design of your machine, the roller compaction system dramatically determines its functionality and efficiency.

As such, you should pay keen attention to this system when choosing any particular roller compactor.

 3.4. Flake Crusher System/Milling System

The flake crusher or the milling system is the part found right under the roller compaction system.

It is the part where the compacted powder from the pressure rollers above are milled/blended into the required shape and size.

This part, has a sieve that only allows the right size of granules to pass through and proceed to the next stage of granulation.

Flake crusher

Flake crusher

When considering the type of flake crusher, it is essential that you do this in consideration of your final product.

What size and shape of product do you want to output?

Whatever answer you give should help you determine what kind of milling system you require.

 3.5. Touch Screen PLC System

This is the operator console or in other words the control panel.

Control panels are a vital part of any modern industrial machines.

Typically, this part is made of a metal plate with a PLC touch screen.

The panel contains indicator lights, toggle switches and a push button that you can use to run the machine.

Control panel

Control panel

The main advantage of the control panel is that it enhances usability.

It generally makes it easy to monitor and control the production process ongoing in the roll compactor machine.

3.6 Variable speed drive system

Like all the other parts we’ve mentioned above, the drive system is an essential component of the roll compactor machine.

It is more like the heart of the machine because, without it, all other elements cannot function.

As you could see from the video above, the drive system is not just a single part.

It is made up of several parts including the:

  • Motor
  • Gear
  • Belt
  • Shafts

All these allow you to control:

  • Speed
  • Torque
  • Acceleration
  • Deceleration
  • Direction of the machine

With an infinite number of speeds, you can choose a rate that suits your product or process.

You need to ensure that it is within the machine’s operating range.

As you can see, it is pretty different from systems with constant speed.

Section of the drive system

Section of the drive system

And the ability to change speeds frequently makes this machine the go-to option for dry granulation.

Why?

Because it optimizes the machine’s process.

This enables it to perform various tasks that help to improve production quality, speed, and safety.

Other parts and components of a roll compactor machine include;

  • Discharge outlet that releases the final product from the roll compactor machine
  • Alarm systems that help to indicate when there is a problem
  • The skeleton that holds all of the parts and components of the device
  • And many others that unfortunately we won’t be able to mention here.

Of course, the exact location of these parts will depend on the design of the machine.

Plus, manufacturers keep updating the designs, incorporate new parts and elements for better functionality and usability.

To know every detail of roller compactor for dry granulation, you should request for product manual.

Now, let’s see how these parts coordinate to ensure efficient and reliable dry granulation process.

Chapter 4: Roll Compactor Working Principle – A Step-by-step Dry Granulation Process

Even before I explain how a roll compactor for dry granulation machine works, please have a quick overview of the image below:

Working principle of roll compactor for dry granulation

Working principle of roll compactor for dry granulation

To be honest, the principle behind roller compaction technology is simple and straightforward.

As you now know, the process of dry granulation is one that transforms powders into granules without using liquid binders.

This process primarily works by compacting and densifying powders to form granules of desirable shapes and sizes.

But how does it do this?

Below is a step by step process of how roll compactor machines work;

Step 1: Particle rearrangement

The first step of roll compaction is ensuring that you have a perfect blend of powder for compaction.

Here, you’ll have to feed the powder simultaneously into the feeding unit while riding it off the displaced air.

How does this work?

You see, in roller compaction, the materialis often fed into the system using an auger system.

This is to help achieve large mass flow rates of the raw material into the roller system.

Feeding material

Feeding material

Economically, this makes lots of sense.

Now, during compaction process, there is always displaced air that comes from the roller system.

This air cannot escape through the roller nip area.

The only way it can escape is through the feed hopper.

When this happens, it prevents the uniform flow of material into the roller system.

Due to this, most roll compactor machines come with a vent on the side of the feeding hopper.

This vent allows for displaced air to exit from the roller system without disrupting the free flow of material from the hopper to the roller system.

Step 2: Feed of raw material

In this step, raw materials are uniformly and efficiently fed into the feeder unit.

The material will flow from the hopper and into the roller system for compaction.

Feeding material to the rollers

Feeding material to the rollers

Depending on the design of the feeding system, the raw powder will be forced down into the two pressure rollers either vertically or horizontally.

All this will depend on the design of the roller and feeding system.

Step 3: Air flows back along the feeding screw

As I have explained in step 1, during compaction, there is often release of air from the powders which have to exit one way or the other.

Since it can’t flow down, it flows back along the feeding screw and out through the displaced air vent as seen in the figure above.

Step 4: Material is forced through to the roller system

Again, there are various types of feeding systems.

Nonetheless, most roll compactor machines use screw feeders which secures a smooth flow of the material from the hopper to the roller systems.

Roller system

Roller system

Because of its design, the screw kind of pre-compacts the material while getting rid of trapped air at the same time.

It then feeds the raw material into the nip area of pressure rollers.

Note that screw feeder systems have variable speeds.

This speed has a direct influence on the roller gap and thus on the compaction capacity of the roll compactor.

Step 5: Powder compaction

Here, the roller compactor compacts material that comes in from the feeder system into flakes, ribbons or sheets.

Please note that the surface of the rollers here has a significant influence on the feed characteristic of the product.

Likewise, the variable speed of the rollers also determines the retention time of the material within the compaction area.

So, we’ve said that compaction of powders happens at this stage and in the gap of the two pressure rollers.

The hydraulic system of the machine transmits intense pressure to the rollers, which then facilitates compaction.

Step 6: Crushing of the flakes/ribbons/sheets

Step 5 above produces compacted powder in the form of flakes, ribbons or sheets.

These then come onto the milling system that reduces the granule size and shape into what is appropriate.

Remember that the mill has a sieve.

This separates the powders into large, required and fine particles.

The large particles remain in the mill for further crushing; the required particles are sieved into the next section of the mill.

Producing flakes

Granules from flakes

The fine particles move to the lower section of the mill where they will be recycled for further compressing.

Step 7: Transfer of the final compacted product

This is the last stage of roller compaction.

Here, the appropriate granule sizes are sieved into the next section of the mill and transferred to the discharge unit.

They are then collected and pack for distribution or for whatever process is next after roll compaction.

So basically, this is the working principle of roller compacter machines.

As you can see, it is not rocket science.

The best part?

Everything is automated.

All you have to do is go to the control panel, key in the appropriate production parameters and let the machine do its job.

Chapter 5: Types of Pharmaceutical Roller Compactor for Granulation

Tablets, pellets, capsules, and granules are the most common forms of administering drug dosages in the pharmaceutical industry.

ThisI must say is due to their convenience and suitability administration as well as delivery of drugs for systemic effects.

Many people are unlikely to have considered the complicated processes that go into the research, development, and production of tablets.

granules to tablets

Granules to tablets

Tablets are a product of the dry granulation process which transforms powders into granules without the use of liquids.

And while dry granulation may also be done by slugging, roller compaction is the most common technique used for this process.

In this case, as materials pass between the two pressure rollers, they are compacted and densified into flakes, or ribbons.

These are then reduced to a uniform granule size by milling.

Dry granulation as earlier mentioned is the best method for processing soluble and thermally sensitive materials.

In this section, therefore, we are going to look at the various types of pharmaceutical roller compactors based on several elements.

So read on;

5.1. Depending on Material Feeding Orientation (Vertical, Inclined and Horizontal Orientations)

A problem that operators experience in roll compaction is bypassed.

This is where some bit of materials remain in the nip region of the roller system for an unspecified amount of time.

Roller orientation is one of the three things that influence bypass in roller compaction processes.

Different orientations of roller compactor

Different orientations of roller compactor

The type of roller orientation in your machine will determine how much or often you’ll experience a bypass of material.

With this in mind, there are three types of material feeding orientations, some of which address this issue.

· Horizontal orientation

This is the most common design roller systems for dry granulation.

And just as the name suggests, the rollers here are oriented horizontally.

You can see this in figure (b).

In comparison to the other two designs, the loss of material due to bypass in horizontal roller orientation is higher.

Due to this, the use of the side seals on compactor deigns has been adopted by various manufacturers to help reduce material bypass.

· Vertical orientation

If your applications involve using low dosages of material, then a vertical roller orientation may work for you.

You can see this is a figure (a) above.

This is mainly because material movement in this design is not dependent on gravity.

As such, there is usually very minimal loss of material to bypass in this design.

· Incline orientation

Rollers of this design lie on the horizontal and vertical plane.

Here, there is usually little to no bypass material during compaction.

Have a look at figure (c) above.

As a matter of fact, using the incline roller orientation tends to decrease bypass by 15-20%.

This is quite significant, particularly where maximum productivity is needed.

Generally, roller orientation as I’ve said earlier influences bypass in roller compaction.

And high levels of the bypass, in this case, is known to cause blend segregation as well as affect material uniformity.

5.2. Twin Pre-compression vs. Single Pre-compression Feed Screw System

The feeding system of a roll compactor machine is significant in ensuring blend uniformity.

It also provides for easy control of processing parameters.

A feed system that provides non-uniform compacts may lead to poor quality of final output.

It may also lead to the generation of excessive fines and uncompact materials which may jeopardize the whole production process.

As I’ve told you before, the feed screw mechanism is most common in roll compactors.

In this regard, you have the option of choosing between twin and single pre-compression for your feed screw system.

Feed screw mechanism

Feed screw mechanism

In which case, the twin pre-compression feeder system works best for broader roller gaps as it can feed it with material more uniformly.

Please note;

Advancements in roll compactor feeder systems have led to the invention of vent feeders.

This system comprises;

  • A stirrer inside the feeding unit that ensures an even flow of material towards the screw feeder.
  • The screw feeder which forces the material down to the gaps between the pressure rollers
  • A vacuum system, which facilities the flow of hard to transport, high voluminous and fluidizing materials.

5. 3 Fixed vs. Variable Roller Gap

A roll compactor has two equal diameter counter-rotating rollers.

Take note that the gap between the roller units determines the efficiency of the dry granulation process.

Fixed vs. Variable roller gap

Fixed vs. variable roller gap

The rollers come in two designs;

· Fixed gap

The fixed gap roller design features a constant and predetermined gap.

Note that the speed of the screw feeder mainly controls the flow of material in this gap design.

As such, the density of compacts you’ll be getting will be entirely consistent.

Understand also that fixed gap system tends to produce ribbons/flakes of the same shape and size.

However, it allows for non-homogenous material feeding, which causes changes in porosity of the compacts produced.

This also causes variations in the roller pressure that could consequently lead to non-desirable changes in the quality of granules produced.

· Variable Gap

Variable gap roller designs come with movable rolls.

These give out an even roller pressure that is accomplished by controlling both the gap width and the screw feeder speed.

The advantage of this roller unit design is that it has a less bypass propensity.

Being able to change the roller gap provides room for adjusting the density profile with the robustness of the granules.

This, in turn, affects the mechanical properties of the tablets, positively.

5.4 Smooth vs. Corrugated Roller Surface

Like roller orientation, roller surface also tends to influence bypass in roller compaction processes.

The surface of the roller is significant in maintaining back pressure on the flow of material.

a-smooth, b-corrugated and c-fluted roller compactor

 a-smooth, b-corrugated and c-fluted roller compactor

This is so that the material does go through the nip region any speedier than the rolls are rotating.

To reduce bypass, therefore, you may want to use a corrugated roll surface in your roll compactor for dry granulation.

Note that there are two main types of roll surfaces used in the pharmaceutical industry.

There are the smooth surfaces and the corrugated roll surface.

The latter, as I’ve just said, is best for reducing bypass.

It’s also convenient for use when compacting aerated, light and fluffy materials when aiming to increase their bulk density.

Smooth roller surfaces are best when looking to minimize sticking problems.

These are the primary variables that determine the suitability of any roll compactor machine for any particular application.

The bottom line?

I believe that with this you can comfortably choose the best pharmaceutical roll compactor for dry granulation.

That said, let’s take a look at the critical parameters of roll compaction.

Chapter 6: Critical Parameters and Design of Roll Compactor for Dry Granulation

The efficiency of a roll compactor machine for dry granulation is dependent two things; the design of the machine and the operating parameters.

Also, the operating parameters tend to have a significant impact on the whole process of dry granulation.

The parameters can affect the feasibility of the process, the compact quality, the flowability of granules and the blend uniformity.

Roller compaction for dry granulation

Roller compactor for dry granulation

So what are the critical parameters and design of roll compactor for dry granulation?

· Compaction Force

Compaction occurs when pressure is exerted on the two counter-rotating rollers.

This force is what is known as the compaction force it has to suffice for the process of compaction to be effective.

Understand that during compaction, the force exerted on the rollers facilitates densification and bonding of particles.

This is what consequently leads to the transformation of powders into compacted ribbons, flakes and sometimes the sheets.

So, when you increase the compaction force to an absolute limit, the density of the compact also increases.

It also increases the particle size as well as the flowability of granules.

When the compaction force is put at its optimal level, the quality of granule increases depending on the mixture of material.

Excessive roller pressure, nonetheless, will lead to the breaking of the compact material, thus compromising the quality of granules.

Besides, when the pressure is beyond the optimum, it can lead to an increase in temperature, thus affecting granulation of heat sensitive materials.

· Roll Gap

The roll gap is the shortest distance between the two counter-rotating rollers of a roll compactor machine.

Interestingly, this is the most critical parameter of roll compaction and the one that needs to be stabilized by the other settings above and below.

Roller gap has a significant effect on the density of compacts and flowability of granules.

This also tends to impact compact’s hardness and blend uniformity.

The effect of the gap majorly arises as a result of the amount of force applied to the rolls and the amount of material that passes between them.

Generally, the compaction force tends to increase as the roller gap decreases and vice versa.

·         Roll speed

Thisbasically refers to the amount of time it takes for the material to be compacted and it has a significant impact on the density of compacts.

The speed of the rollers should be set and changed according to the screw speed and the flow of materials.

Note that a higher roller speed leads to inadequate compaction of materials.

It also can also lead to blend segregation and consequently loss of blend uniformity.

· Screw speed

The feeder screw speed is another critical parameter of roll compactor for dry granulation.

Like the roll speed, feeder screw speed is dependent on:

  • Flow of material
  • Roller speed
  • Roller gap.

A low screw speed can cause inadequate deposition of material into the nip region.

This can result in the formation of weak compacts.

A high screw speed, on the other hand, can lead to an increase in temperature within the roller unit.

This can lead to melting or caking of particles during movement.

Please note;

Using high screw speeds won’t solve an inadequate flow of materials.

You should always maintain an optimum speed for the horizontal and vertical screw.

This will help you to achieve homogenous compaction for your materials.

Also, always remember to keep the screw speed equal to the roller speed.

· Milling

If you want to reduce the size of densified materials, you need to apply more compaction force.

Steadily increasing the pressure can help you achieve the desired size of granules, uniformity of blends and good flowability of materials.

The sieve in the milling system can also affect the particle size distribution which can also impact the granule uniformity.

Excessive fines generated in the milling process can densify the blend and affect flowability.

This can also affect the uniformity of blends as well as compact hardness during compression.

6.2. Main Technical Specifications of Roll Compactor

The technical specification of any machine determines its capability to perform its intended functions.

In this case, they help determine the ability of a roll compactor machine to process specific products.

Note that that unlike most features of an industrial machine, technical specifications like the name suggests are usually specific to a particular model.

And, understanding the technical specification of a roll compactor imagine can help you understand its suitability for your products and processes.

Keeping this in mind, here is a table indicating the main technical specifications of roll compactor machines.

SpecificationUnit Description
ModelType of machine based on manufacturer’s product line. For instance, at SaintyCo we have RC-150C and RC-5B series
Feed screw speedRPMThe speed at which the feed screw rotates.
Roll  speedRPMThe speed of a step pulley drive
Roll drive motorKW or HPPower consumption
Feed screw drive motorMotor power consumption
Type of rollKW/HPThis describes the surface of the roll which may be smooth or corrugated
Roll forceKg or tonsMaximum compaction force
Roll diametermm or cmSize of the roll
OutputKg/hourThe quantity of processed material the machine produces per hour

 

There are other specifications that we’ve not mentioned in this table. But like I said, each model has its specs.

And these are just the main ones that you should be looking for when buying a roll compactor machine.

Chapter 7: SaintyCo Roll Compactor Machines for Dry Granulation

SaintyCo is a global leader in designing and manufacturing roll compactor machines.

And so far, SaintyCo roller compactor machines are among the best in the material processing industry.

We have over 20 years’ experience in manufacturing and supplying roller compactor for dry granulation.

SaintyCo roll compactor machines are both cGMP and CE compliant. Also, they are robust and manufactured from high grade stainless steel.

What’s more?

We take quality seriously, and it is easy to see this even in the picture of our products.

Our roll compactors for in particular are made from robust stainless steel structures.

With fully automated system, expect seamless dry granulation thereby eliminating possible errors due to human intervention.

SaintyCo roll compactor machines are built to last, ensure even particle distribution and increased bulk density for dry granulation.

Some of our main machines include:

· SaintyCo RC-100 Roll Compactor

Ideally suited for laboratory applications, this machine will help you achieve excellent uniformity, even particle distribution, and increased density.

It will also help you increase your overall output regardless of your resources.

SaintyCo RC 100 Roll Compactor

SaintyCo RC-100 Roll Compactor

This RC-100 roll compactor model is just perfect for processing highly soluble and thermally sensitive materials.

With this, you can be guaranteed of achieving 99.99% effectiveness.

· SaintyCo RC-150 Roll Compactor

This RC-150 roll compactor is compactly designed to suit the requirement of pharmaceutical and food processing industries.

The machine is sturdy enough to crush and compact material into the desired density and size.

SaintyCo RC 150 Roll Compactor Machine

SaintyCo RC-150 Roll Compactor Machine

This model comes with a horizontal screw feeder, two-stage granulation, and a circulating cooling system.

The compact design of this SaintyCo RC-150 roll compactor makes it easy to use, clean and maintain.

So, if you need a machine that guarantees you precise and consistent dry granulation, this is it.

You can have it custom made or choose from the standard units we have available.

· SaintyCo RC-200 Roller Compactor Pharmaceutical

The SaintyCo RC-200 roll compactoris explicitly designed for pharmaceutical use.

It comes with varied roller designs and a hydraulic control system that allows it to dry granulate a wide range of materials.

SaintyCo RC-200 Roll Compactor Pharmaceutical

SaintyCo RC 200 Roll Compactor Pharmaceutical

Like the RC-150 model this RC-200 machine also features a horizontal screw feeder system.

This ensures precise and consistent material feeding into the roller compaction unit.

Designed in compliance withcGMP standards, this machine is available in both custom and standard designs.

· SaintyCo RC-V100 Roller Compactor

This is an advanced machine specially designed for densifying and granulating a wide range of materials in laboratory applications.

SaintyCo RC V100 Roll Compactor

SaintyCo RC-V100 Roller Compactor

The RC-V100 roll compactor machine comes with a wide range of features.

These include;

  • POD display
  • Easy, quiet and accurate operation
  • Maximum pressure of 120 bar
  • The vertical material feeding system

Like all of SaintyCo products, you can have your RC-V100 machine in custom or standard design.

· SaintyCo RC-V200 Roller Compactor

This RC-V200 roll compactor machine best suits pharmaceutical, R&D, and foodstuff applications.

It features a fully automatic system with a PLC control panel that allows you to operate it smoothly and efficiently.

SaintyCo RC-V200 Roller Compactor

SaintyCo RC-V200 Roller Compactor

The design of this machine is just perfect as it is dust tight, compact and modular.

Besides, it features a vertical feeding system for consistent material feeding.

· SaintyCo RC-5B Roll Compactor

RC-5B Roll Compactor is a robust, compact and portable equipment designed for R&D and small batch production.

It has 4 wheels, small touch screen control panel and a stainless steel structure.

RC-5B Roll Compactor

RC-5B Roll Compactor

Like other SaintyCo roll compactor machines, the RC-5B Roll Compactor is cGMP and CE compliant equipment.

Conclusion

I believe this guide has been useful in helping you understand more about roll compactor machines for dry granulation.

It has covered everything, from roller compactor design, specifications, working principle and many more.

If you have any questions about roller compactor for dry granulation, feel free to leave a quick comment below.

You can also email us for further inquiries.

Further reading:

  1. Working Principle of Pharmaceutical Roller Compactor
  2. Benefits of Roller Compactor in Material Processing
  1. Optimization of Roll Compaction
  2. Overview of Roller Compaction and Dry Granulation
  3. Handbook of Pharmaceutical Granulation Technology