ROLL COMPACTOR

WHY IS COMPACTION NECESSARY?

• To improve bulk density.
• To achieve better granulation of sieve analysis.
• To reduce process cost and improve end product quality.

PRINCIPLE OF COMPACTION:

This is a dry granulation method. The basic concept is to force fine powder into solid compact or sheet. Some of the factors controlling the compaction process are roll's surface, diameter, peripheral speed, separating force & pressure capabilities, feed screw and basic compaction characteristics of the material being process addition of binders to the material being processed. Greatly reduces the production of fines.

AN OUTSTANDING FEATURE :

• Totally G.M.P, compact design - plain as well as water Jacketted for products which are extremely sensitive.
• Various types of rolls can be offered to suit your specific application so as to achieve maximum bulk density of output eg. (A) plain (b) corrugated (c) briquetted & (d) knurled.
• Specially designed feeding system consisting of hopper predensifier and a variable speed drive unit Safety clutch is provided to prevent any accident.
• Feeding unit can be hydraulically lifted by hand-operated hydraulic pump for easy cleaning and maintenance.
• Built-in panel and indicators are provided, on-off, feed screw, main switch, forward/reverse switch RPM indicators for roll and feed screw, emergency stop, digital RPM indicator etc.
• Specially designed scraper is provided to prevent powder sticking on the rolls.
• Design of the equipment is such that minimum lubrication is required in daily maintenance.
• Main roll drive is designed with twin shaft gear box coupled with safety clutch to protect roll drive thereby perfectly synchronizing the rolls with a steady torque.
• The side seal is forced against the roll side, so that the percentage of uncompacted powder that leak is kept extremely low.
• To prevent a possible accident the compacting roll is designed to rotate backward when cleaning.

N.B.: Can offer free trials at our factory before purchase decision is taken.

Process

BASIC REQUIREMENT FOR TABLETING

SAVE QUALITY OF ACTIVE MATERIALS:

Dry Granulation Process saves the quality of active raw-materials at its best. Material remains safe of Oxidation / Reduction / Temperature / Atmospheric hygroscopic absorbences.

SAVE INSTALLATION OF RELATED EQUIPMENTS & SPACES. :

Dose not require Drying equipments on account of Compaction Process. So Drier Equipments & Spaces are saved.

SAVES POWER INSTALLATIONS & CONSUMPTION. :

Power Requirements is only 7 H.P. compared to account of Compaction to more than 50 H.P. for Fluid Bed Drier. Power Conservation Comparative Study for Processing of 500 Kgs.

granules proves :

Wet Granulation -
ROLLER COMPACTOR MACHINE = SAVING
246.5 KW/HR. 34 KW. HR. = 212.5 Kw. HR.

SAVES MAN POWER. :

Wet Granulation -
ROLLER COMPACTOR MACHINE = SAVING
22.5 man./ hr. 8 man./ hr. = 14.5 Kw. HR.

INCREASE PRODUCTION CAPACITY BY 1 TO 3 CRORES OF TABLETS.

Serrations X Rpm X Weight X Minute X Work Time
     60        X   5    X     3      X     60    X       6               
  =  Compacts/Granules Output
       324 Kgs. ( 10-25 Lac Tab. )

EASY & PERFECT CLEANING ON CHANGE OVER.

Machine Design permit perfect cleaning in just 15 minute time. Machine Design permit cleaning with WATER HOSE PIPE & SOAP WATER.

REDUCES INDUSTRIAL HAZARDS. :

Alternative Production Process requires use of Non - Aqueous Binders that Causes INDUSTRIAL HAZARDS OF - FIRE - COST - HUMAN DAMAGES. which is saved on account of dry Granulation Processing.

DRY GRANULATION MADE PRODUCTIVE & EFFICIENT.

Alternative Slugging Equipments have - Cumbersome Operation - Less Efficient Slugging. - Low Productivity.

READY FORMULATION SUGGESTIONS.

Backed by Actual Involvement in manufacture of various Formulations from one of the Directors of the company.

Detail:-

Roll Compactor Machine is used for dry granulation method. It forces the fine powders between two counter rotating rollers and presses the fine powders in a solid compact or sheets, so called chips or flakes. Finally these chips or flakes are then reduced in size to the desired granules/grain size further with the help of Oscillating Granulator Machine or Multi Mill Machine or Comminuting Mill or Sizing Machine. The sieve size should be selected very carefully in order to prevent the generation of fines. The selected sieve defines the final granules/grains size. Also further to achieve excellent granules/grains can be made dust free by Screening (Sifter) Machine. The separated fines also can be Re-compacted/ Recycle with Roll Compactor Machine.

In the process of compaction the fine powder or crystalline powder are fed to the charging hopper of the Roll Compactor. Here the vertical feed screw feeds the powder into the compacting zone of the compacting rollers through the pre-compacting chamber. The adjustable speed (through AC Variable Frequency Drive – AC VFD) of feed screw pressures the powder to pass strictly between the compacting rollers gap and therefore strong/hard chips/flakes forms from the fine or crystalline powder. After proper synchronization of Roller Speed & Feed Screw Speed with proper flakes quality, the same speed ratio can be continue to achieve the more output (if the speed limit permits the machine rated roller & feed screw speed) from the same machine model.

The Roller surface can be selected depending upon the characteristics of the powder/product. If the products are well familiar with the Roll Compactor Machine, our Technical Team can suggest the perfect roller surface for the particular product base on an experience & expertise for it. For product development or evaluation of product or changing the concept of granulation method, or achieving the dust free granules in order to get the Export quality granules, we are always happy to carry out the trails with your material in our plant.

SALIENT FEATURES:

• In Compliance with cGMP guidelines.
• Contact Parts are made of S.S. 316 except rollers.
• Very compact design available in Plain, Water Jacketed or Flameproof Model.
• Screw is driven through AC Variable Frequency Drive. Safety slipping clutch between gearbox and feed screw.
• ELNP (Electroless Nickel Plating) or Hard chrome plated with mirror finished compacting rolls made of tools steel.
• Rolls drive through twins shaft gearbox with drive unit coupled to it using coupling, which ensures synchronization of the rolls with a steady torque loading.
• Pre-Compression chamber guides the products to roll without any slippage or leakage.
• Pre-densifier screw comprises of cylindrical or conical shape, which is well polished and made of AISI SS-316 quality material.
• The feed screw assembly can be lifted by hand-operated hydraulic pump. This facilitates ease in cleaning.
• Scrapper assembly also designed to dismantle for ease of cleaning.
• A separate panel board which consist all controls and indicators of the compactor are permanently built in namely, on/off rolls, on/off feed screw, main switch, forward/reverse switch, ammeters for rolls and feed screw and emergency stop to avoid short circuit or fire hazard at the time of cleaning with water.
• Electrical interlocking between main roll drive and fixed screw drive.
• Water jacketing arrangement. (optional)
• Hydraulic power pack system for Rear Roller. (optional)
• AC Variable frequency drive for Rollers. (option

Technical Specifications:

* Depending upon material characteristic & available room atmosphere only.
NOTE : DUE TO CONTINIOUS IMPROVEMENTS IN THE MACHINERIES, SPECIFICATION OF THE MACHINERIES IS SUBJECT TO CHANGE WITHOUT ANY PRIOR NOTICE.
Dia : Diameter / W : Width