Niro Pharma Systems

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• Niro Pharma Systems
• Leading Technologies Delivering Competitive
  Advantages

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DWELL LENGTH/TIME DIFFERENCE AT PRE-COMPRESSION
WITH OR WITHOUT ACTIVE COURTOY PRE-COMPRESSION
COMPENSATOR

• Definition used
• Dwell length starts when 100 of the
  pre-compression force is achieved and ends when
  the pre-compression force starts to drop. Dwell
  length is independent of press speed and
  therefore used in this presentation. When the
  press speed is know the Dwell Time can be
  calculated.
• Without the active Courtoy air compensator, 100
  of the pre-compression force is achieved ONLY
  when the pre-compression roller dwells on the
  flat surface of the punch head.

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UPPER PUNCH CONTACT WITH PRE-COMPRESSION ROLLER
WITHOUT ACTIVE COURTOY AIR COMPENSATOR
REPRESENTATION OF UPPER PRE-COMPRESSION ROLLER
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1
REPRESENTATION OF UPPER PUNCH
Initial contact between punch and Upper
Pre-compression roller.
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UPPER PUNCH CONTACT WITH PRE-COMPRESSION ROLLER
WITHOUT ACTIVE COURTOY AIR COMPENSATOR
2
2
The punch is forced into the die the
pre-compression force increases.
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UPPER PUNCH CONTACT WITH PRE-COMPRESSION ROLLER
WITHOUT ACTIVE COURTOY AIR COMPENSATOR
3
3
Start of Dwell Length
The roller starts to dwell on the flat of the
punch head and then the downward stroke of the
punch has ended. The pre-compression force will
remain constant until the roller leaves the punch
head flat surface. This point marks the beginning
of the dwell at 100 of the pre- compression
force.
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UPPER PUNCH CONTACT WITH PRE-COMPRESSION ROLLER
WITHOUT ACTIVE COURTOY AIR COMPENSATOR
4
4
Start of Dwell Length
During the contact between the roller and the
flat of the punch head the pre-compression force
will remain at 100.
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UPPER PUNCH CONTACT WITH PRE-COMPRESSION ROLLER
WITHOUT ACTIVE COURTOY AIR COMPENSATOR
5
5
Start of Dwell Length
End of Dwell Length
The roller ceases to dwell on the flat of the
punch head. The pre-compression force will drop
very fast and is a function of the elastic
recovery of the pre-compressed tablet.
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UPPER PUNCH CONTACT WITH PRE-COMPRESSION ROLLER
WITHOUT ACTIVE COURTOY AIR COMPENSATOR
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Total dwell time on Non Courtoy Press
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INCREASED DWELLTIME DUE TO DISPLACEMENT SYSTEM
P is controlled and kept constant by a
proportional valve Spiston is the calculated
surface of the piston. Therefore the force
applied to the yoke by the air pressure is FP
x S piston constant
The image above shows the Top Pre-Compression
Roller Assembly on a Courtoy Pharma press. The
yoke that holds the pre-compression roller can
slide up and down in the cylinder. The constant
air pressure in the cylinder holds the yoke
against its dead stop as long as the pressure in
the cylinder exceeds the reaction force from the
powder transferred through the punch to the yoke.
When the reaction force from the powder equals
the force applied to the yoke by the air-pressure
but the punch stroke on roller is not completed,
the roller will move upwards for a distance equal
to the vertical component of the stroke.
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COURTOY AIR COMPENSATOR
1
PRE-COMPRESSION FORCE
1
TIME
Initial Contact between Punch and Upper
Pre-compression roller.
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COURTOY AIR COMPENSATOR
2
2
The punch is forced into the die the
pre-compression force increases.
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COURTOY AIR COMPENSATOR
3
3
Start of Dwell Length
At this point the reaction force from the tablet
equals the air pressure x the compensator surface
in the air compensator. This will end the
downward stroke of the upper punch and initiate
the roller to movement upwards. The roller starts
to dwell on the flat of the punch head. The
pre-compression force will remain constant until
the roller leaves the punch head flat surface.
This point marks the beginning of the dwell at
100 of the pre- compression force.
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COURTOY AIR COMPENSATOR
CONSTANT FORCE COMPRESSION
ROLLER MOVEMENT
4
Start of Dwell Length
4
Pre-Compression force can NOT increase roller is
pushed up!
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COURTOY AIR COMPENSATOR
CONSTANT FORCE COMPRESSION
MAXIMUM ROLLER MOVEMENT CALLED DISPLACEMENT
OCCURS WHEN PUNCH AND ROLLER CENTERLINES ALIGN
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Maximum roller movement is called DISPLACEMENT
Start of Dwell Length
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COURTOY AIR COMPENSATOR
CONSTANT FORCE COMPRESSION
ROLLER MOVEMENT
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Precompression force is maintained..
Start of Dwell Length
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COURTOY AIR COMPENSATOR
TOTAL DWELLLENGTH
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ROLLER BACK INTO LOWEST POSITION, READY FOR NEXT
PUNCH
Start of Dwell Length
End of Dwell Length
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CALCULATION OF DWELL LENGTH EXTENSION
Dwell length extension using Courtoy
Compensator R² (R-d)² (D/2)² (D/2)² R² -
R² 2dR d² d² almost 0 D/2
(2dR)½ D 2(2dR)½ Calculated example on Courtoy
Modul Roller diameter 240 mm so R 120
mm Average displacement 0.25 mm D
2x(2x0.25x120) ½ 15.5mm For B TSM tooling Flat
on punch head is max 9.3 mm. Dwell length without
displacement 9.3 mm Dwell length with
displacement 9.3 15.5 24.8mm almost 200
increase !!!!!!. Dwell time is a function of the
press speed and increases with the same as
Dwell length.
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ADVANTAGES OF EXTENDED DWELL TIME

• Higher production output for dwell time sensitive
  products.
• Leads to better de-aeration and uniform
  distribution of the granule in the die and punch
  cups prior to final compression of the tablet.
• Higher hardness, for equal disintegration time.
• Reduced risk of capping, better bonding of layers
  on Bi-layer tablets.

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