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Impact of roll compaction design, process parameters, and material deformation behaviour on ribbon relative density

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Ribbons comprising microcrystalline cellulose (MCC), mannitol, and a 50:50% mixture of both were generated utilizing the roll compactors AlexanderWerk BT120, Hosokawa Alpine Pharmapaktor C250, L.B. Bohle BRC 25, and Gerteis Mini-Pactor as part of multilevel full factorial experimental plans. The quantitative factors analyzed included specific compaction force (SCF)/hydraulic pressure (HP), gap width (GW), roll speed, and the fraction of MCC, while roll surface and sealing system were examined as qualitative factors. The response variable in the models was the relative density of the ribbons. The SCF/HP emerged as the most significant factor in each model. A noteworthy inverse effect of the GW was observed in the models of AlexanderWerk BT120, Pharmapaktor C250, and BRC 25 roll compactors, employing smooth rolls. The concept of introducing a conversion factor (cf) is proposed based on the data sets obtained from AlexanderWerk BT120 and Mini-Pactor. This approach aims to facilitate the transfer of a roll compaction process between different types of roll compactors.
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