Jcb Roller Compactor
Karren Bangura
Whether you need to achieve a specific particle size and distribution for tablet compression, or mill heat-sensitive materials, Fitzpatrick can provide the best solution to fulfil your specific processing objectives.
Recognized as the most trusted name in roller compaction technology and dry granulation equipment for more than 70 years, our customers are supported by world-leading applications and development experts, offering budget-friendly, industrial-strength, high-performance roll compactors for dry granulation processing, with each new generation of machinery incorporating seven decades of knowledge.
Fitzpatrick roller compactors offer a truly scalable equipment growth path. As customers progress from research & development all the way through to full production, results obtained on smaller models are fully transferable to larger systems.
With continual investment in customer-driven innovative solutions to address market needs, Fitzpatrick provides long-term global support via their highly technical customer service and spare parts network.
Acknowledging that each individual process requires specific roll compactor operating features, Fitzpatrick offers two distinct model ranges; the IR (Interchangeable Rolls) Series and the CCS (Contained Compaction Systems) Series.
The CCS-Series provides a truly scalable equipment growth path. Offering high containment, progress from R&D to full-scale, high-capacity production-scale models, with fully transferrable results at each stage.
The IR-Series of roller compactors offers different scales of production capacities from pilot to full-scale production systems, offering the flexibility to increase powder density and enhance flow characteristics.
High Containment Roller Compactor models, fully contained and scalable from lab to production. Our unique dual-screw feed system design ensures the ideal conditions are created right from the outset at the critical nip area of the rolls.
Designed with three rolls, the CCS320 model is a compact, mobile unit which is easily movable. With consistently sized roll diameter across the CCS-Series of machines, scale-up to production size equipment is easily achieved.
The CCS520 model is available as a free-standing or in-wall installation. In-wall installations minimize clean room space requirements and allow for internal maintenance access without the need for PPE.
The CCS720 model is available as a free-standing or in-wall installation. In-wall installations minimize clean room space requirements and allow for internal maintenance access without the need for PPE.
The CCS1025 model is the largest capacity of the CCS range of roller compactors and comes as a free-standing or in-wall installation. With the in-wall design, the technical area is entered from the back for ease of use and does not require any PPE.
For applications requiring a reduced level of containment, our IR-Series affords varying options of production capacities from pilot-scale to full-scale. Recognized worldwide as high-performing technology for Dry Granulation, the IR-Series offers the flexibility to increase powder density and enhance flow characteristics, improving downstream performance results.
The LCS is a low-volume benchtop system that processes powders with the same pressure as larger production-scale roller compactors. With a choice of roll surfaces, this machine is manufactured with a high-precision, twin feed screw system which ensures your development projects can progress from the lab to production with confidence.
Granulation is a process in which powder particles are made to adhere to each other, resulting in larger, multi-particle entities, so called granules. If such a process is performed without adding liquids, this is called dry granulation.
\nIn dry granulation, the powder blend is compacted by applying a force onto the powder, which in general causes a considerable size enlargement.
\nThe compacts\u00a0obtained are called ribbons, flakes or briquettes.
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\nIn order to obtain the desired granules, the compaction process is followed by a milling step.
If a tablet press is used for the compaction process, the term slugging is used. But since particles with a small particle size do not flow well into the die of a tablet press, resulting in weight differences from one tablet (slug) to another. This in turn causes large fluctuations in the forces applied onto the individual slugs, and variability in the mechanical strength of the slug. Therefore, the properties of these granulates obtained by milling the slugs cannot be controlled.
\nThis is one of the main reasons why slugging is rarely used as a dry granulation method.
The powder is compacted between two rolls by applying a force, which is the most important parameter in the dry granulation process. The applied force is expressed in kN/cm, being the force per cm roll width. Occasionally the press force is also indicated in bar. This, however, merely represents the pressure within the hydraulic system, and is in fact not an appropriate measuring unit for the force applied onto the powder.
At a given force, depending on the amount of powder conveyed to the rolls, the powder will be compacted to a predefined ribbon thickness.
\nA precise process control is essential to obtain uniform granule properties from a homogenous ribbon. For more on that topic see section PAT below.
Roller compactors can be divided into two categories: One is equipped with a fixed gap, the other one with a floating gap. Both consist of the three major units as explained above but differ in the way in which the smallest distance (gap) between the rolls is realized.
When a fixed gap is installed, the amount of powder drawn in into the compaction area between the rolls is inconsistent, which results in varying forces applied to the powder bed. Like slugging, this will cause large fluctuations in the ribbon and granulate properties.
With floating gap (e.g. GERTEIS\u00ae-Machines) the distance between the rolls change according to the amount of powder provided. The force applied to the powder remains constant. This ensures that property fluctuations in the granules are reduced to a minimum.
With our integrated models, the ribbons are milled immediately after compaction using a screen with a given mesh size, thus limiting the upper particle size.
\nThis milling process should be performed as gently as possible, so as to avoid creating excess fines.
The GERTEIS\u00ae roller compactors are able to control and measure all product quality relevant parameters (e.g. force, gap and roll speed) on-line in order to fulfill the requirements of the pharmaceutical industry for a well-controlled and documented manufacturing process. All the parameters are calibrated and validated. Additionally, in order to cope with batch to batch variations, our machines are fitted with control systems to allow equal granule properties during manufacturing according to PAT.
Dry granulation is used for increasing the bulk density of powders, while increasing the particle size, resulting in better flowing material, which is a prerequisite for manufacturing capsules and tablets on high speed production equipment.
\nFurthermore, bonding the particles of various substances together during the compaction process reduces the tendency to segregation of powder particles of different substances. This results in an improvement of the homogeneity of the active ingredients (API) within the powder blend, causing an improvement of dose uniformity of such dosage forms.
In contrast to wet granulation, dry granulation is a truly continuous process. This results in various economic advantages. Currently the throughput of common dry granulation systems can reach approx. 400kg/h.
\nDry granulation systems require lower capital investment in facilities or equipment. This, together with much lower maintenance requirements results in drastically reduced lifecycle costs.
\nThanks to countless and ongoing innovations nearly\u00a0all dry powders can be processed on a GERTEIS\u00ae dry granulation system.
Further Advantages of Dry Granulation are:
\n- Minimal floor space
\n- Large throughput of material (highly efficient process)
\n- Truly continuous process
\n- Highly energy efficient; no heat for drying and no air conditioning required as for other granulation techniques
\n- Ultra High Containment Options are available to avoid contamination of manufacturing areas and personnel from high potent actives
\n- Low running costs
Weber MT is an industry leader in paver compactor and soil compactor machines and equipment. These rammers, forward plate compactors, reversible plate compactors, and slab roller compactors speed up soil and paver work for hardscaping projects. When it comes to laying pavers, paver compaction machinery vibrates the pavers into the ground, setting them and helping to ensure uniformity in the installation.
Our Weber MT hardscaping equipment collection includes a wide range of walk behind hydraulic control compactor machines, reversible soil compactors, paver compactors, slab rolling compactors, and gas-powered rammers.
Weber MT also offers COMPATROL, the first continuous compaction control system. The system can read and direct the vibration of the compactor's base plate according to soil conditions. These results are displayed to the user and let you know when optimal compaction has been achieved.
For pavers, it's important to use a compactor that is specifically designed for said application. Weber's MT line of paver compactors provide the power and precision needed to ensure proper compaction for your next project. To get started on your paver project, reach out to the compaction equipment experts at Pave Tool Innovators.
When choosing a compactor for pavers, there are three options. Forward plate compactors, reversible plates, and paver rolling compactors. If compacting large slabs the only option is a slab rolling compactor, designed not to crack or break the stones, but still effective enough to set your slabs for a smooth surface as well as vibrate the sand into the joints. Compacting regular-size pavers with all options with a compaction force of 4,000 lbs. or more is an appropriate fit. And with any plate compactor, you are going to want to get a Poly Pad to protect the pavers from scratching.
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