Bouncing Roller Compaction
Bouncing roller compaction (BRC) is a type of compaction process used in the production of pharmaceuticals including tablets and pellets. In this process, a pair of rollers compress a powder mass into tablets or pellets of a desired shape and size. The process is used to form tablets that are larger than those made from single punch compaction.
This process is also sometimes referred to as “double-roller compaction.”
The most significant advantage of using BRC is its ability to efficiently compress a powder mass into tablets or pellets rapidly. This is achieved by the interaction of two pressure points along the length of a roller. In addition, the BRC process has the ability to control the compaction profile.
The process of BRC takes place in four steps: pre-compaction, primary compaction, secondary compaction, and final compaction. The pre-compaction step is used to break up large chunks of material and homogenize the powder. During primary compaction, the powder mass is compressed under a high pressure and then relaxed before continuing the compaction process. This is the most effective stage of the BRC process, as it creates a uniform distribution of powder, resulting in pellets or tablets with a consistent size and shape.
Secondary compaction is used to refine the pellets/tablets further by alternating high and low pressure. This allows for better control over the shape and size of the tablets or pellets, as well as achieving a smoother surface. The final compaction stage is used to further compress the pellets/tablets and to ensure that they meet the desired specifications.
The key feature of the BRC process is its ability to create tablets and binding pellets. The process provides the highest compaction pressure amongst all types of roller compaction processes and provides superior mechanical integrity of the pellets/tablets. The process also allows for the creation of porous tablets which can be used as a dosage form for active ingredients that are susceptible to environmental degradation.
In terms of the process parameters, the gap between the rollers needs to be adjusted appropriately to achieve the desired level of compaction. The material in front of the rollers should have a specific moisture content in order to allow the compaction process to occur efficiently. The speed of the rollers should also be adjusted in order to increase or reduce the frequency of the pressure points.
The BRC process provides an efficient, safe, and repeatable means for attaining large tablets and pellets. The process allows for precise control over tablet morphology and size as well as providing a higher degree of mechanical integrity than other methods of tablet manufacturing. The use of the process is increasing as more pharmaceutical companies work to reduce production costs due to the increasing demand for big tablets and pellets. The process is also becoming increasingly popular for applications including food supplements, industrial materials, and nutraceuticals.
