Roller compactor for continuous dry granulation

Continuous roller compaction has been a well-established method in the pharmaceutical business for decades, and it is used for more than just moisture and temperature-sensitive products.

Unlike traditional wet granulation techniques, this approach does not require any energy-intensive drying operations, which eliminates the need for substantial investments in systems and production facilities and reduces batch costs.

Roller Compaction is often the preferable method for highly bulky or moisture-sensitive products. L.B. Bohle’s BRC roller compactors are capable of continuous production and can be combined with Process Analytical Technology (PAT). As a result, the BRC series granulators provide flexibility for integration into a wide range of production settings.

Granulation with the L.B. Bohle Roller Compactor

L.B. Bohle’s BRC roller compactor combines high product capacity with minimal material loss. This system outperforms its rival solutions by generating force through purely electromechanical means to ensure consistent ribbon properties.

Using highly innovative methods, the BRC is able to regulate compacting force and ribbon thickness. It compacts material uniformly over a production range of < 1 - 400 kg/hour. 

The advanced system design makes handling easier and shortens the assembling procedure. The hygienic design and integrated washing nozzles, which come as standard, enable an efficient WIP procedure.

Despite high material throughputs, the cone-shaped BTS Bohle Turbo Sieve mill and sieve inserts softly crush ribbons into granules with the required particle size distribution. Each BRC roller compactor can be retooled with an alternate rotary sieve in minutes to meet the changing process and ribbon requirements.

The roller compactor satisfies the pharmaceutical “Quality by Design” criteria due to its functional GMP-compliant design and support for PAT tools.

Roller compactor for continuous dry granulation

Image Credit: L.B. Bohle Maschinen und Verfahren GmbH

Benefits of the Roller Compactor

  • Precision control of compression force using a unique electromechanical roller drive results in little material loss
  • Maintaining consistent ribbon characteristics
  • Easy to use and quick setup
  • Hygienic design and efficient cleaning with WIP nozzles (‘washing in place’ method)
  • The integrated Bohle Turbo Sieve (BTS) allows for versatile and gentle particle size calibration
  • Particle size calibration with integrated Bohle rotation sieve (BRS)
  • Optional PAT integration
  • Optional containment equipment, including sampling

Variations and technical features

L.B. Bohle provides roller compactors in a variety of sizes and technical configurations.

An initial overview and comparison of the array of roller compactors for the granulation is provided in the list below.

Source: L.B. Bohle Maschinen und Verfahren GmbH

Machine BRC 25 BRC 100
Capacity [kg/h] ≤ 1 – 100 kg/h (product dependent) ≤ 1 – 400 kg/h (product dependent)
Size (LxWxH) [mm] 1900 x 1000 x 1960 1960 x 1410 x 2140
Operator panel Siemens touch panel  

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