Roller Compaction Dry Granulator

The roller compaction dry granulator transforms powdery materials that are prone to airborne dispersion, have low density, and poor flowability into granular products with high density, excellent flowability, and no dust through physical processes such as pelletizing, crushing, and sieving. It is widely applicable in pharmaceuticals, chemicals, and food industries for granule production.

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Description Of Roller Compaction Dry Granulator

The roller compaction dry granulator is a type of powder dry granulation equipment.

Roller compaction granulation is a process of compressing and agglomerating loose powder, and then crushing and granulating the compacted powder to improve the fluidity of the powder. It is suitable for process production such as tableting, capsule filling, etc.

Compared with wet granulation, the advantage of dry type granulation is that it does not require the participation of water or other organic solvents in the entire process. It is especially suitable for drugs that are sensitive to moisture and heat. In addition, the bulk density of the material is greatly increased, thereby reducing consumption,control environmental pollution, while reducing packaging costs and improving the operating environment for workers.

Roller compactor is technically easier to realize automatic control, has high efficiency, simple process and is more environmentally friendly.

The grannule size, hardness and shape can be adjusted.

Advantage Of Roller Compaction Dry Granulator

Material is mechanically compressed under force, eliminating the need for any wetting agents and ensuring product purity.

Environmental pollution is controllable, reducing powder waste and packaging costs, while enhancing product transportability.

Feeding and feeding devices utilize variable frequency stepless adjustment control, with high automation allowing for single-person control over multiple machines, low labor intensity, and long-term continuous operation.

Granules exhibit high strength and significantly increased bulk density compared to other granulation methods, making it particularly suitable for increasing product bulk density.

Direct granulation of dry powder eliminates the need for subsequent drying processes, facilitating seamless integration and modification of existing production processes.

Compact structure, easy maintenance, simple operation, short process flow, low energy consumption, high efficiency, low failure rate, wide range of applicable materials, and freely adjustable roller pressure according to different materials.

Main drive components are made of high-quality alloy materials, stainless steel, titanium, chromium, and other surface alloys, greatly improving wear resistance, corrosion resistance, high temperature resistance, and pressure resistance, resulting in a longer service life for the machine.

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Specification Of Roller Compaction Dry Granulator

Vertical Roller Compaction Principle

Various dry powder materials are introduced from the top of the equipment. After degassing and pre-pressing by the screw, they enter between two equal rollers. The rollers rotate relative to each other, forcing the material between them. The rollers compress the material as it enters the nip, and after passing through the compression zone, the material naturally exits due to surface tension and gravity. The resulting ribbon-like chunks enter the granulator and are crushed by rotating blade sets. The crushed material then enters the pelletizer, where rolling blade sets separate particles and some powdery material for sieving. Qualified products are conveyed to the finished product warehouse. Powdered material under the sieve is sent back to the raw material warehouse via a conveyor for secondary roller compaction, with the compression force adjustable by the pressure of hydraulic cylinders according to granulation requirements.

Horizontal Roller Compaction Principle

Raw materials are fed through a feeding port into a bucket elevator via a screw conveyor. The bucket elevator delivers the powdered raw materials to a raw material bin. A volumetric feeder transfers the material to a variable-frequency screw feeder for pre-compression. Pre-compressed material is forced between two pairs of opposing rotating rollers to compact it. The compaction force is transmitted to the material through hydraulic cylinder thrust applied to the rollers. The compacted flakes automatically discharge into a crusher, where they are broken into uneven-sized granules. The granules then enter a pelletizer for refinement. The refined granules are extruded through a sieve plate with mesh into a screening machine. Finished granules are conveyed to the finished product warehouse via a bucket elevator. Powdered material separated during screening is returned to the raw material bin via a screw conveyor for re-compression, completing a closed-loop cycle.

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Application Of Roller Compaction Dry Granulator

Various chemical raw material powders: Various inorganic salt fertilizers, flame retardants, chemical raw material powders.

Metal smelting additives: Magnesium chloride and other salts, iron oxide powder, manganese powder.

Various food additive powders: Starch, foaming agents, sodium sulfate.

Water treatment agents: CMCC, fish medicine, antioxidants, disinfectants, etc.

Petroleum treatment agents: AMPS, etc.

Deicing agents: Sodium formate.

Feed additives: Various amino acids, betaine, organic and inorganic additives.

Battery materials: Lithium iron phosphate, ternary materials, graphite, lithium carbonate, etc.

Mineral materials: Talcum powder, tungsten powder before calcination, limestone.

Roller Compaction Dry Granulator FAQ

Common problems and solutions during dry granulation process

Common problems in the dry granulation process include:
High proportion of granules and fine powder, uniformity of compression, and material sticking to the roller.
1.The proportion of fine powder is relatively high: one solution is to use a grooved roller, and the uncompacted material usually leaks out from the side of the roller; the second method is to re-compress the fine powder. There is a risk, but repeated compaction of the material may cause it to lose its compressibility and affect the quality of the tablets; the third solution is to install vacuum degassing equipment.
2.Uniformity of compression: The pressure on the surface of the roller is not uniform. Even the pressure on materials in the same area will change with time. The fluctuation of pressure is mainly affected by the compression structure of the roller and the uniformity of the feed of the mixed material. Influence. The solution to the roller compression structure is to use a roller with narrow wheels on the edge to reduce the movement of the compressed material and make the material evenly distributed; the solution to the uniformity of the mixed material feed is to adjust the screw feeder speed and adjust the fluidity of the mixed material.
3.Material sticking to the roller: The problem of material sticking to the roller is relatively simple and can be solved by controlling the moisture content of the mixed material, adding lubricant, and repeated extrusion.
Factors affecting dry granulation process

Generally, there are three main variables in the dry granulation rolling process: pressure, feed screw speed and roller speed; there are two main auxiliary materials in the mixed powder that have a greater impact on rolling: binders and lubricants, and easy Affected by the moisture content of the material.
1.The moisture content of the material affects: the deformation and tensile strength of the material, thereby affecting the compressibility of the tablet; therefore, during the dry granulation process, the moisture content must be strictly controlled even for the same material.
2.Influence of lubricants: The addition of lubricants will affect the compressibility of some materials. The amount and method of adding lubricants are the two most important aspects that affect the compressibility of tablets. In addition, the crystal form of the same lubricant and The specific surface area also affects the compressibility of the mixture.
3.Influence of binder: Binder can compensate for the loss of particle hardness, reduce the amount of fine powder during dry granulation and ensure the tensile strength of tablets; the correct selection of binder is important for the dry granulation process, especially For brittle API materials, particle size distribution is a key material attribute of adhesives.
4.Influence of roller pressure: When the roller pressure is low, the difference in compressibility loss for the same material is very small, but when the roller pressure is high, the compressibility loss of the same material will be large. Particles prepared at lower pressures have more pores and are more likely to break during tableting, resulting in high compressibility.
5.Influence of physical properties: Many APIs and excipients have different physical forms, including polymorphs, solvates, and amorphous forms. Even for the same material, there are batch-to-batch differences, such as particle size distribution, morphology (crystal form, crystal habit, agglomeration), surface roughness, etc., which will also affect the compressibility of the material during the dry granulation process.