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Niro Pharma Systems Leading Technologies Delivering Competitive Advantages. FLAT SURFACE ON PUNCH HEAD. REPRESENTATION OF UPPER PUNCH. DWELL LENGTH/TIME DIFFERENCE AT PRE-COMPRESSION WITH OR WITHOUT ACTIVE COURTOY PRE-COMPRESSION COMPENSATOR. Definition used:

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niro pharma systems leading technologies delivering competitive advantages
Niro Pharma Systems

Leading Technologies Delivering Competitive Advantages

slide2
FLAT SURFACE ON PUNCH HEAD

REPRESENTATION OF UPPER PUNCH

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.

slide3
PRE-COMPRESSION FORCE

TIME

UPPER PUNCH CONTACT WITH PRE-COMPRESSION ROLLER WITHOUT ACTIVE

COURTOY AIR COMPENSATOR

REPRESENTATION OF UPPER PRE-COMPRESSION ROLLER

1

1

REPRESENTATION OF UPPER PUNCH

Initial contact between punch and Upper Pre-compression roller.

slide4
PRE-COMPRESSION FORCE

TIME

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.

slide5
PRE-COMPRESSION FORCE

TIME

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.

slide6
PRE-COMPRESSION FORCE

TIME

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%.

slide7
PRE-COMPRESSION FORCE

TIME

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.

slide8
PRE-COMPRESSION FORCE

TIME

Start of Dwell Length

End of Dwell Length

UPPER PUNCH CONTACT WITH PRE-COMPRESSION ROLLER WITHOUT ACTIVE

COURTOY AIR COMPENSATOR

6

Total dwell time on Non Courtoy Press

6

slide9
COURTOY PNEUMATIC COMPENSATOR

air cylinder

air pressure:P

piston surface: Spiston

dead stop

piston

upper

pre-compression roller

upper punch

reaction force of the compressing powder on the punch

INCREASED DWELLTIME DUE TO DISPLACEMENT SYSTEM

P is controlled and kept constant by a proportional valve

Spistonis the calculated surface of the piston.

Therefore the force applied to the yoke by the air pressure is

F=P 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.

slide10
COURTOY

AIR COMPENSATOR

1

PRE-COMPRESSION FORCE

1

TIME

Initial Contact between Punch and Upper Pre-compression roller.

slide11
PRE-COMPRESSION FORCE

TIME

COURTOY

AIR COMPENSATOR

2

2

The punch is forced into the die: the pre-compression force increases.

slide12
PRE-COMPRESSION FORCE

TIME

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.

slide13
PRE-COMPRESSION FORCE

TIME

COURTOY

AIR COMPENSATOR

CONSTANT FORCE COMPRESSION

ROLLER MOVEMENT

4

Start of Dwell Length

4

Pre-Compression force can NOT increase: roller is pushed up!

slide14
PRE-COMPRESSION FORCE

TIME

COURTOY

AIR COMPENSATOR

CONSTANT FORCE COMPRESSION

MAXIMUM ROLLER MOVEMENT CALLED DISPLACEMENT OCCURS WHEN PUNCH AND ROLLER CENTERLINES ALIGN

5

Maximum roller movement is called DISPLACEMENT

Start of Dwell Length

5

slide15
PRE-COMPRESSION FORCE

TIME

COURTOY

AIR COMPENSATOR

CONSTANT FORCE COMPRESSION

ROLLER MOVEMENT

6

Precompression force is maintained…..

Start of Dwell Length

6

slide16
PRE-COMPRESSION FORCE

TIME

Total dwell lengthon NON COURTOY presses

Total dwell lengthonNON COURTOY presses

COURTOY

AIR COMPENSATOR

TOTAL DWELLLENGTH

7

ROLLER BACK INTO LOWEST POSITION, READY FOR NEXT PUNCH

Start of Dwell Length

End of Dwell Length

7

slide17
Standard dwell length

Extended Dwell length using Courtoy Compensator

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.

advantages of extended dwell time
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.
slide19
EXTENDED PRE-COMPRESSION PROFILE

WITH ACTIVE COURTOY AIR COMPENSATOR

PRE-COMPRESSION PROFILE

WITHOUT ACTIVE COURTOY AIR COMPENSATOR

P.S. Above curve is valid for presses set to achieve equal pre-compression force.

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