What Is Compaction Force in Tablet Compression Machine?

1.What is compaction force in tablet compression machine?

Compaction Force In Tablet Compression Machine- Picture Courtesy: BASR Pharma

It is a mechanical force that is solely concerned with compaction of powders or granules in the die cavity of tablet compression machine. With the help of this force powders are transformed into compact and intact tablets. These pills meet the specification of the strength, hardness, and shape with the utility of compression pressure.

The bulk volume of powdery or granular material is reduced in compression and arrange loose powder mixture into cohesive structure by instigating particle arrangement, deformation, and, bonding. Due to compaction force in tablet compression machine particles move in the vicinity of each other and develop strong attractive forces, leading to formation of solid tablet mass.

2.Why is understanding compaction force in tablet compression machine integral for pharmaceutical manufacturing?

Compaction force is responsible for keeping tablets compact and resistant to disintegration. Therefore, it is must to understand the compaction force in tablet compression for attaining quality and potent tablets. Let’s learn about the reasons of learning about compaction force:

Uniform Tablet Quality

Uniform Tablet Quality- Picture Courtesy: SOTAX

Understanding compaction force is pivotal in forming tablets with uniform hardness, weight, and thickness. Thus, you can regulate the intensity of these forces, to ensure that resultant tablets satisfy every predefined criterion of tablet properties. Furthermore, you can exert correct amount of force to prevent problems, for instance, capping, lamination, or breaking during handling, shipment, or packaging.

Proper Dose Accuracy

Proper Dose Accuracy- Picture Courtesy: LFA Tablet Presses

By learning about compaction force, you can estimate proper amount of force used for tableting. This will uniformly distribute active drug components within the tablets. This will lead to proper dosage accuracy without any possibility of over- or under-dosing.

Boosts Tablet Strength

Boosts Tablet Strength- Picture Courtesy: SOTAX

Without proper understanding behind the principle of compaction force, inadequate compaction force will be applied to powders or granules that cause tablets to break apart and fragment, increasing rejection rates. But with adequate force and strong bonding, tablets of high mechanical strength and developed, which can tolerate rigors of handling or shipment.

Cut Down Product Losses

Cut Down Product Losses- Picture Courtesy: Pharma Excipients

Optimized compaction force in tablet compression machine will generate tablets that qualify every quality control test for hardness, dissolution, and friability. This results in distribution of more tablets to packaging stage and reducing wastage of tablets. Moreover, a thorough information of tablet compaction force will decrease downtime due to tablet defects, consequently resulting in efficient tableting cycles.

Aids Research and Development

Aids Research and Development- Picture Courtesy: SOTAX

Comprehending the association between the compaction force in the tablet compression machine and tablet characteristics facilitates the preparation of formulation and powder blends with suitable compressibility and fluidity. Hence, you can tweak the starting materials, granulation approaches, and binder amount depending upon the preferred compaction profile.

3.How is compaction force produced in a tablet compression machine?

You would be intrigued about how compaction force is generated in a tablet compression machine and its specific mechanisms. It is an important force generated by various moving parts in the tablet compression machine. They exert steady pressure to blended materials to turn them into compact tablets.

This compression process utilizes a sophisticated combination of various mechanical and operational controls to accurately regulate the compression force within the die cavity. The mechanisms for production of compaction force in tablet compression machine is mentioned below:

Hydraulic Pressure Mechanism

Hydraulic Pressure Mechanism

In this system, hydraulic pressure mechanism is utilized to apply pressure on the static fluid, which then transmit in all directions. The piston system in hydraulic press is used to apply force on tooling assembly for its movement that generates the compaction force. It comes with advantages of finetuning of pressure to adjust compaction force magnitude.

Cam-Driven Mechanism

Cam-Driven Mechanism- Picture Courtesy: IMA Pharma

It has a rotating cam arrangement that moves punches up and down with its rotation. When materials are transferred to die cavity then usually, the upper punch descends down to exert downward compaction force on the materials, while lower punch holds them in place and usually ascends upward for tablet ejection.

It is used in the high-speed and mass-scale facilities due to its high working speed. Compaction force is modified according to preference by changing the rotational settings of cam.

Screw Mechanism

Screw Mechanism- Picture Courtesy: IMA Pharma

With the aid of motor or other mechanical systems, the screw is rotated. This screw has tiny threads that interact with nuts or other enclosures to induce linear motion of punches. Consequently, the compaction force is created in the tooling assembly and presses the feed against immobile die or opposing punch. This system produces considerable compaction force to make high-density tablets.

4.How is compaction force measured in a tablet compression machine?

Estimating the amount of compaction force in tablet compression machine is crucial aspect of the tableting process and with this you can ensure that formed tablets align with highest standard of quality and meet the regulatory specification. How can you measure this force?

We are detailing different approaches to measure compaction force for your knowledge:

Load Cells

Load Cells

They are the tiny transducers, furbished on the compression rollers, punches or main frame of the tablet compression machine. They can estimate the amount of compaction force by converting it into mechanical signal. Typically, with application of the compaction force, a deformity or change in shape of load cell occurs. This leads to alteration in electrical resistance of load cells and is changed into quantifiable signal. This signal is measured by load cell that offers information on compaction of materials in real-time.

Stain Gauges

Stain Gauges- Picture Courtesy: Federal Equipment Company

They are narrow strips of conductive substances that modify electrical resistance when are elongated or tamped. They are present on the parts, for instance, punches or bearing. It spots deformation in the punches or other components during material compact and offers indirect measurement of exerted compaction force.

Pressure Sensors

Pressure Sensors- Picture Courtresy: Nutrition Group

Sometimes, the devices for measuring the compaction force in tablet compression machine are embedded in the hydraulic mechanism or pneumatic system. Pressure sensors are employed for determining the pressure of the hydraulic fluid. This pressure is equal to amount of compaction force applied on punches.

Torque Sensors

Torque Sensors- Picture Courtesy: PSI Software

As the name indicates, they are employed for measuring the rotational torques on compression rollers. They are found in rotary tablet press and estimate the degree of force transferred through rollers. It offers indirect estimate of the compaction force.

Displacement Sensors

Displacement Sensors- Picture Courtesy: Fve.International

They infer the compaction force by detecting the displacement motion of punches. They are installed on punches and uses light and electromagnetic induction coil to determine the compaction force.

5.How does punch and die configuration affect compaction force in tablet compression machine?

The punch and die configuration have major part in controlling the compaction force. It governs allocation of pressure, the load of material compressed, and quality of end tablets. Some ways by which punch and die configuration affect compaction force are mentioned below:

Geometry and Size of Punch and Die

Geometry and Size of Punch and Die

Flat-shaped punches are integral in uniform distribution of compaction force across powder bed, whereas, the concave-shaped punches are usually utilized for exerting compaction force around edges or central parts of tablets. They create tablets with embossed pattern or unique shapes.

Die with larger sizes can hold more volume of material, therefore, need substantial force to compact powders. The die with smaller sizes needs less compaction force but face more wear and tear because of excessive stress.

Tapered Die

Tapered Die- Picture Courtesy: YENER KALIP

It has a mildly conical opening to mitigate friction during compression and ejection steps. With this design, you can minimize the needed compaction force and reduced damage on punches.

Punch Tip

Punch Tip- Picture Courtesy: Elizabeth Companies

What is a role of punch tip in production of compaction force? If you need more precise tablet shapes, you can utilize sharp tip punch. It develops stress concentration; thus, higher compaction force is required for tableting. On the other hand, round tip punches are ideal for homogenous distribution of compaction force. Engraved punches utilized for creating tablets with logos or marking need excessive compaction force to force pattern into final tablets.

Tooling Configuration

Tooling Configuration- Picture Courtesy: Elizabeth Companies

B-tooling has smaller physical size, making it prefect for applications that needs low level of compaction force, for instance, manufacturing of smaller-sized tablets. D-tooling has larger size, appropriate for production of larger tablets, therefore, needs more magnitude of compaction force.

6.Is compaction force in tablet compression machine influence tablet hardness and friability?

Hardness and friability of tablets- Picture Courtesy: World Pharma Today

Without a doubt, a compaction force in tablet compression machine has a significant effect on the tablet hardness and its friability. How can this be? Well, let’s look at details of mechanism by which compaction force influence tablet hardness and friability.

Tablet Hardness

It is the characteristics of tablet that indicates its ability to tolerate mechanical strain without cracking, fragmenting, or splitting. If you apply higher compaction force, it will compress the particles more tightly, thereby, boosting the strength of inter-particle bonding. This creates higher tablet hardness. Conversely, decreased compaction force lowers the bonding strength between granules and produces softer tablets.

Keep in mind, do not exert excessive compaction force, as it can create tablet defects, such as capping or lamination and also decrease disintegration rate.

Tablet Friability

It is defined as the measure of tendency of tablets to fragment, chip, or disintegrate when exposed to increased mechanical pressure or adversities of shipment or handling. With higher compaction force, you can have enhanced particle bonding, which decrease friability and therefore, tablets are less likely to crack, fracture, or chip. However, lower compaction force on powders or granules produces weak bonding between particles, increasing tablet friability and dust production.

Compaction force in tablet compression machine must be correctly balanced to acquire ideal proportion of hardness and friability.

7.Does compaction force in single-punch and multi-punch tablet compression machine differ from each other?

Compaction force in single-punch and multi-punch tablet compression machine- Picture Courtesy: Truster-Pharma

Yes, there are some significant differences between compaction fore in single-punch and multi-punch tablet compression machines. As, these machines differ in their engineering and operational mechanism, therefore, compaction force varies in utility dynamics and control in both of these equipment. Some of the differences are discussed below:

Features	Single-Punch Tablet Compression Machine	Multi-Punch Tablet Compression Machine
Force Mechanism	It utilizes single upper punch to compact the powder. Typically, compaction force is exerted vertically on the materials.	There are multi array pf punch (upper and lower) punch to convert powdery or granular feed into tablets. The compaction force is exerted concurrently by both upper and lower punches.
Timings	It involves one compaction cycle in one interval; hence, it is simple to adjust and control compaction force in this equipment.	Multiple punches are moving to compress numerous tablets in one compression phase, so, more precise calibration of compaction force is required to attain homogeneity across every tooling unit.
Force Uniformity	In single punch tablet compression machine, the uniformity of compaction force is much greater, as there is only one pair of tooling.	There are significant differences in compaction force in multi-punch tablet compression machine because of turret alignment as well as punch damage.
Compression Speed	This instrument runs at low speed, thus there is more time for materials to compact materials. There is more time for application of compaction force.	This device runs at higher speed, consequently, there is reduced interval during which compaction force is applied to consolidate particles.
Force Adjustment	It is easier to alter the compaction force in this device to obtain optimal results.	It requires automated systems and calibrated sensors to adjust compaction force.

8.What is the difference between precompression force and compaction force in tablet compression machine?

Precompression of Tablets

Transformation of powdery or granular substances is possible due to both pre-compression force and compaction force in tablet compression machine. They both are integral to tableting process and work together to attain optimal quality tablets. It is a common misconception that they are identical to each other. However, there are some significant differences between these forces due to their magnitude, function, and time. Now, let’s have an insight on their distinct roles:

Features	Precompression Force	Compaction Force in Tablet Compression Machine
Definition	This force is applied to powder or granular mixture beforce the actual compression process. It has lower intensity and its exertion serve as a initial step in the tableting procedure.	It is the main compaction force exerted during the primary compression step to change blended feed into cohesive unit or tablets.
Purpose	It has diverse functions, for instance, elimination of entrapped air molecules within the powder bed. It uniformly dispenses starting feed in the die cavity and also has a role in the particle arrangement, which increases the contact areas between particles for optimal bonding during the compression stage.	Its main function is to bond the particles with adequate pressure to form high-tensile strength and undamaged tablets. This compact force is responsible for determining the hardness, porosity, and disintegration profile of tablets. Due to this stronger force, particles are strongly bonded and do not break apart or crumble during logistics and distribution.
Intensity	Its magnitude is much smaller than primary compaction force and typically is about 0.1–1 kN (kilonewtons).	Its intensity is much higher than pre-compression force and is about 1–50 kN or more. Its magnitude is typically determined by size, ingredients, and desired strength of end-tablets
Timing	It is exerted at the beginning of the compression cycle, prior to movement of the punches under the compression rollers.	When the punches moves under the compression rollers then this force is applied- instantly after the precompression force.
Tableting Impact	It is necessary for preparing the starting feed for smooth and flaw-less compression. It starts the compaction process and partially compacts the feed.	It establishes the structural integrity of formed tablets, so that they conform to specified physical and mechanical criteria.

9.What are quality control instruments for compaction force in tablet compression machine?

There are various quality control instruments that indirectly quantify compaction force in tablet compression machine. Some of these devices are listed below:

Tablet Hardness Tester

Allpack Tablet Hardness Tester

A tablet hardness tester is a specialized device with remarkable features to quantify the hardness of tablets. It indirectly determines the compaction force by estimating the durability of tablets and resistance. The tablet is placed between two corresponding jaws and force is subjected to crush tablets. The force value until its breakage is recorded and gives the estimate of hardness.

The hardness is indicator of compaction force exerted to formulate tablets in manufacturing process.

Tablet Friability Tester

Allpack Tablet Friability Tester

It is utilized to estimate the tendency of tablets to crumple, chip, split, or crack upon strenuous stresses of logistics and supply chain. Tablets are rotated in drum that mimics the strains faced by products during shipment or handling. After run, weight loss is measured to determine friability.

More weight loss means more friability that in turn shows insufficient compaction force to compact materials.

10.What are common challenges to control compaction force in tablet compression machine? How to address them?

How to attain quality and consistency in tablet batches? Simply, by accurately controlling the application of compaction force in tablet compression machine. However, there are wide array of challenges that make this process quite troublesome. However, there is no need to worry because we are describing these challenges and also stating their solutions.

Inconsistent Powder Fluidity

Inconsistent Powder Fluidity- Picture Courtesy: Indpro Engineering Systems

Irregular powder or granule loading into die cavity results in differences in weight and density. This leads in variability in the magnitude of the compaction force.

Solution

You can fix this issue by using flow enhancers, for example, colloidial silica to improve powder flow. Also, you can modify design of hopper or feeder to obtain even flow. It is recommended to use granules with consistent size range to increase fluidity.

Material Characteristics

Modification in Material Properties- Picture Courtesy: Jenike & Johanson

Sometimes, you compress materials that have low compressibility, stick to surface of punches, or have diversity in their particle sizes. This creates a variable compaction force and it is difficult to maintain it at steady level.

Solution

It is a significant challenge encountered by numerous manufacturers; however, it is simple to solve it by incorporating diverse kinds of binders or lubricants to boost the compressibility behavior. Also, you can study your starting feed attribute by carrying out pre-compression test.

Environmental Conditions

Environmental Conditions- Picture Courtesy: I Holland

Are there excessive humidity or temperature fluctuations in your facility? If yes, then it can alter the material traits, for instance, its fluidity or moisture amount. Due to this the compaction profile of materials is altered.

Solution

You must main stable environmental setup by installing air ventilation systems, air conditioners, or dehumidifier to keep physiochemical properties of materials from changing. Also, it is advised to store powder or granular blend in moisture-proof containers.

Granule Segregation

Granule Segregation- Picture Courtesy: Jenike & Johanson

Are your granular matter keep segregating? It could certainly alter the consistent filling of die cavity. This cause irregularities in tablet weight, hardness, as well as compaction force. With segregation of granules in different sizes or density profile, it will be difficult for you to apply controlled steady compaction force on granules.

Solution

This challenge is easily addressed by employing correct blending protocols and adequate blending time. This will result in homogeneity of blending. Moreover, utilize well-establish granulation approaches to form uniform-sized and density granules. Incorporate baffles in hopper to decrease rate of segregation.

Sticking of Powders

Sticking of Powders- Picture Courtesy: Huada Pharma

Do you observe material sticking to punches? It averts the exertion of homogenous pressure and cause application of inconstant compaction force across the die cavity. Furthermore, it enhances buildup of frictional force, hence, more compaction force is needed to compact powders or granules.

Solution

To resolve this problem, you must utilize anti-sticking agents, for instance, magnesium stearate. Secondly, adjust granulation process to attain correct moisture level in granules. Tablet press tooling must be clean and well-maintained to avoid sticking problem.

Conclusion

In conclusion, the compaction force in tablet compression machine is a secret ingredient that transforms a load of powder into solid, functional, and potent tablets. It is not just about compacting the feed- it’s about exerting the prefect balance of compaction force to create strong, hard, and unform tablets that serve their therapeutic purpose. Moreover, using right amount of force, you can avoid tablet brittleness, chipping, cracking, laminating, or, friability. It is a delicate balance of precision, science, a light dash of art. If you need to learn more or in need of tablet compression machine then contact AIPAK to obtain promote response on your queries and orders.