Bultmann's Roll Compaction-site
on Dry Granulation


Key parameters

The two main process parameters that contribute to ribbon porosity are
1) specific compression force and
2) gap size.
Roll speed (next to gap size and roll width) is the main factor only in regard to efficiancy of the system (expressed as throughput per time unit).

Figure: Key parameters of the roll compaction process

Figure: Porosity is mainly influenced by ribbon thickness and specific compresion force (left), not by roll speed (right)

Thus the handling of a dry granulation system seems to be quite easy:
Force and gap have to be set and the process can be started.

There’s only one major obstacle: The gap can not be “set” directly; it is the result of the amount of powder presented to the nip area, the force and the roll speed (the amount of powder converted into a ribbon and taken out of the rolls). Thus in order to obtain the desired gap size, one has to control the auger speed instead.Force and auger speed are set in order to obtain the desired porosity (the actual connection depends on the powder’s compactability) while roll speed should be low. Auger speed should be very low to stay on the safe side and force should be also in the lower region for the same reason. If too much powder is conveyed to the nip area, the rolls are moved to the side until the maximum possible gap size is reached and machine stops itself to prevent hardware demage. 
When the gap slowly opens and reaches a steady state, auger speed can be adjusted in order to obtain the desired gap size. Then force should be set to the desired value and automatic control can be activated.


Additional parameters

A well equipped roll compactor offer a lot more parameters to adjust. An in depth description of each parameter is not given here.