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Pharma roller compaction concepts
More than three decades of constant development and innovation has made Gerteis® of Switzerland an internationally respected expert force in roller compaction concepts.The versatility of renowned Gerteis pharmaceutical roller compactors, including Polygran®, Macro-Pactor® and Mini-Pactor® support compaction of all kinds of powders, even the most difficult ones at all scales.
Roller compaction concepts
Granulation is a process in which powder particles are made to adhere to each other, resulting in larger, multi-particle entities; ‘granules’. In order to obtain the desired granules, the compaction process is followed by a milling step.
Wet granulation describes this process performed while adding liquids while in dry granulation, the powder blend is compacted by applying a force onto the powder, which in general causes a considerable size enlargement.
The compacts thus obtained are called flakes or ribbons.
In contrast to wet granulation, dry granulation is always continuous process. This results in various economic advantages, not least increased throughput with dry granulation systems reaching 400 kilograms per hour (kg/h).
Dry granulation systems also require comparatively fewer investments into buildings or equipment. Coupled with lower energy requirements and maintenance costs, this results in a much higher overall profit.
Gerteis pharma roller compaction platforms
Gerteis offers five different pharma roller compactor solutions, tailored for a range of needs from proving laboratories to high containment production.
Macro-Pactor®: Gerteis’ flagship pharma roller compactor solution, is designed and engineered for scale up from development to high speed production at up to 400kg/h and a very wide range of press force, roller speed and gap settings. Engineered around an open star rotor, closed pocket type granulator with integrated bulk-breaking and precrushing for optimal compaction results, Macro-Pactor also features real-time process control, perfect sealing system to reduce uncompacted fines and complies with CFR 21 Part 11 requirements. MacroPactor also incorporates Interfaces for pneumatic or mechanical conveyor systems, feed and discharge for high containment applications.
Mini-Pactor®: Gerteis’ laboratory roller compaction solution incorporates the same high quality engineering and granulator design in a more compact package designed and engineered for pharma laboratory development, while also handling pilot projects and small scale production batches. Mini-Pactor features constant ribbon properties, validated gap and force measurement and low OEL levels, under 3µg/m³. There are various options like the conveyer, feed and discharge interfaces needed to support high containment applications.
Ultra-Pactor®: a high-end pharma roller compactor engineered for ultra-high containment applications, supporting OEL levels of under 0.1 µg/m³, while still offering throughputs up to 400kg/h. Ultra-Pactor guarantees optimal protection for the operator against highly active and hazardous substances with glove ports, ATEX-compliancy and the optional ability to purge N2 into the process area. It also features permanent monitoring of all sealing and pressure zones, along with fully automated CIP facilities.
Polygran®: A pharma roller compactor oriented towards production and value for money, featuring simplified handling and controls for high accessibility. Ingeniously engineered powder feeding and parts assembly. These allows Polygran to support medium production quantities with throughputs of up to 300kg/h.
Mini-Polygran®: an ultra-compact and highly mobile pharma roller compaction solution that strikes an ideal balance between performance and flexibility. The unique Mini-Polygran setup of individual machine parts allows ultra-rapid maintenance and changeover from batch to batch, with hassle-free scale-up to production volumes of up to 50kg/h. The machine can be supplied with four-castor mobile trolley frame for flexible placement within the laboratory.
Click on Pharma roller compaction principles to access original Gerteis White Paper and technical bulletins.
Schematic of Gerteis roller compaction method showing: (1) Inlet funnel with agitator, (2) Feed auger, (3) Tamp auger, (4) Small quantity inlet funnel, (5) Press rollers with ribbon, (6) Rotor with desired granules.
Gerteis Macro-Pactor®: flagship pharma roller compactor
Gerteis MINI-PACTOR®: optimized for laboratory development and small-scale production