Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
At the same production rate, duration of tableting events depends on roll diameter, pitch
circle diameter, number of stations, punch geometry, length of feed frame and the angle
of ejection ramp. On the other hand, the speed of various tableting events becomes a
limiting factor in press productivity.
However, the same consolidation time will, most probably, ensure the same tablet
quality, or, at least, bring the process to a close proximity of the target.
Calculate at what speed (RPM) different production presses can offer the
minimum satisfactory consolidation time, and what tablet output can be expected
from different presses at that speed.
Algorithms and formulas of the MCC Tableting Calculator are based on extensive list of
published papers and on our own investigations into the geometry and dynamics of
tableting. Some sources are listed in Tableting.pdf in the c:\sc folder created on your
computer after software installation (you will need an Adobe Acrobat Reader to access
this file). We suggest that you read this file in its entirety before proceeding with this
tutorial.
Please note that sometimes the resulting fields are blank. Than means that not all press
parameters are available in the database for calculations. If you need to calculate
Tutorial for Scale-Up Calculator, Version 2.0 Page 1 of 24
compaction variables for such a press, please contact MCC for more information. We
will try to find the missing press parameters and update the database.
In the reports, when a calculated field is blank, this may also mean that the press can
not reach the requested velocity (e.g., it is outside the range of attainable speeds for
this particular tablet press).
Definitions
Feeding Time, Tf. Time when the die is fed with powder.
Consolidation (Solidification) Time, Ts. The portion of Contact Time when punches are
changing their vertical position in reference to the rolls decreasing the distance between
their tips.
Dwell Time, Td. The portion of Contact Time when punches are not changing their
vertical position in reference to the rolls.
Decompression (Relaxation) Time, Tr. The portion of Contact Time when punches are
changing their vertical position in reference to the rolls increasing the distance between
their tips before losing a contact with the rolls.
Compression Time, Tp. The portion of Contact Time before the decompression period
begins (Tp = Ts + Td).
Contact Time, Tc. Time when both punches are moving having their tips in contact with
the material that is being compacted, and their heads are in contact with the pressure
rolls (Tc = Ts + Td + Tr).
Ejection Time, Te. Time when the tablet is being ejected from the die
The notion of dwell time is largely misused or misunderstood. In fact, it should be used
as a yardstick, a measure of linear (that is, tangential or angular) velocity and therefore
it will depend on the punch geometry. The speed comparisons based on the dwell time
assume that the punch has a flat head. The velocity then is the dwell time divided by the
length of that flat portion. For the same linear velocity, the smaller is the punch head
flat, the smaller is the dwell time. To everyone’s surprise, dwell time for dome-shaped
punch heads is practically zero by definition, regardless of press linear velocity or RPM.
That is why, compared to dwell time, linear velocity is a better measure of press speed.
Calculations of dwell time in the MCC Tableting Calculator are based on a length of a
punch head flat. By default, this value is conventionally set at 9.3 mm (R3, radius of the
punch head flat = 4.65 mm). Since the flat portion is surrounded by a curvature, some
published sources use different values. You can change the length of the flat portion of
the punch head by adjusting the R3 parameter on the MCC Tableting Calculator screen.
When you have to select a tablet press, you can use the MCC Tableting Calculator to
compare press output at the same consolidation time Ts that is the most crucial part of
the compression cycle.
For example, on Panel 1, select Fette PT 2090 IC 36 station press and move the speed
slider to produce 100,000 TPH (that would correspond to 46.3 RPM or 20.2 ms
consolidation time). As before, we set R3 = 4.65, d = 0.015, F = 3.0, Hf = 6 mm, Hi = 3
mm (these parameters affect either Consolidation time, or Dwell Time, or both).
Now, on Panel 2, select Kikusui Libra2 36 single sided station press to obtain Ts = 20.2
(that would correspond to 90,000 TPH or 41.7 RPM).
Now, switch to the “Match Mode” and select Kikusui Pegasus 1036 36 station press on
Panel 2. You will see that, for the same consolidation time of 20.2 ms (108,669 TPH,
50.3 RPM), the Pegasus press makes more tablets and is more efficient (Es = 0.61)
than the Fette 2090.
A blank cell or “?data” in the report indicates lack of data in the database. If the value of
Ts + Td is not equal to 29.6, it means that this particular press cannot reach the desired
speed (either the press is too slow or too fast).
Yet another matching parameter may be the Av, the Average Punch Vertical Velocity
per unit horizontal displacement that, some say, may be a good descriptor of a
compaction event. We offer the Av calculation for completeness. However, based on
our experience, we are of the opinion that Ts + Td is best suited for scale-up or product
transfer.
On Panel 1, select, for example, a Kilian TX 30A tablet press, and move the speed
slider to get Ts + Td = 22 ms (this corresponds to 73.2 RPM).
Hit “Report” button to produce an Excel report listing all tablet presses at a fixed Ts +
Td.
From the report, it will be evident, for example, that the Ts + Td = 22 ms can be reached
by Kikusui Gemini 1545 at 257,840 TPH (Td = 10.2 ms), and by Fette 2090 36 station
press at 134,300 TPH (Td = 7.0 ms). It means that Gemini will make more tablets at the
same consolidation + dwell time with a larger dwell time.
If the press you have does not appear in the table, let us know, and we will update the
data base for you.
For example, for ρ = 600 kg/m3, η = 0.0021 Pa*s (at Viscosity Factor = 7.40E-
04), h/d = 0.539, n = 500 RPM, R = 0.11 m, a = -0.72, b=4.5, the end-point
values are calculated to be (click “Calculate Net Impeller Power” button):
For example, if the “viscosity factor” for your specific mixer was found to be
0.000625, click “Enter New Viscosity Factor” and enter the number. For n =
400 RPM, R = 0.4 m, enter 385 into the “Enter Net Impeller Power” window
and click “Calculate Viscosity” button. The results are calculated to be:
For example, using powder weight m=1.2 kg, liquid density ηL = 1000 kg/m3,
bowl volume Vb = 4 l, rate of liquid addition = 21 ml/min, time of liquid addition
= 270 s, and leaving the liquid volume field blank, press “Calculate Fill Ratio”
button to see the following result:
Note that this value now became visible in the “Fill Ratio” field ready to be
used for other calculations.
______________________________________________________________________
Disclaimer: Although an utmost diligence was used to compile press and mixer-granulator data, human
errors may happen. Please bear in mind that MCC will not be legally responsible for any such errors in
calculations.