Effect of roll compactor sealing system designs: A finite element analysis

In the pharmaceutical industry, the roll compaction is part of the dry granulation process, densifying fine powders into ribbons that will be later milled to produce granules with good flowability for subsequent die compaction process. Roll compactors are constructed with a sealing system, limiting the loss of powder from the sides. However, the sealing system may result in unwanted non-uniformity of the ribbon's properties. In this work, a 3D Finite Elements Method (FEM) modeling is used to analyze the roll compaction process and the effect of sealing system designs on the compacted ribbon's density distribution. A density dependent Drucker–Prager Cap (DPC) constitutive model for microcrystalline cellulose (Avicel PH-101) was calibrated and implemented in Abaqus/Explicit. Two different FEM models were investigated, one with a fixed side sealing called cheek plates and another where the side sealing is integrated with the bottom roll called rimmed-roll. Both numerical and experimental results clearly show the non-uniform roll pressure and density distribution for the cheek plates assembly, whereas the rimmed-roll shows an overall more uniformly distributed resultant pressure and density distribution. These results demonstrate the capability of FEM modeling to provide insight and help achieving a better understanding of the roll compaction process. [Display omitted] •We study the effect of roll press sealing designs on ribbon's density distribution.•Predictive 3D FEM modeling is compared to measured data.•The use of cheek-plates results in higher density in the middle than in the edges.•The use of rimmed-roll results in lower density in the middle than in the edges.