Compaction analysis and optimisation of convex-faced pharmaceutical tablets using numerical techniques--颗粒学报PARTICUOLOGY

Baroutaji, A., Lenihan, S., & Bryan, K. (2019). Compaction analysis and optimisation of convex-faced pharmaceutical tablets using numerical techniques. Particuology, 47, 10-21. https://doi.org/10.1016/j.partic.2018.11.002

Compaction analysis and optimisation of convex-faced pharmaceutical tablets using numerical techniques

Ahmad Baroutaji ^a *, Sandra Lenihan ^b, Keith Bryan ^b

a School of Engineering, Faculty of Science and Engineering, University of Wolverhampton, Telford, UK
b School of Mechanical, Electrical and Process Engineering, Cork Institute of Technology, Cork, Ireland

10.1016/j.partic.2018.11.002

Volume 47, December 2019, Pages 10-21

Received 26 August 2018, Revised 24 October 2018, Accepted 5 November 2018, Available online 10 April 2019, Version of Record 7 December 2019.

E-mail: ahmad.baroutaji2@mail.dcu.ie

Highlights

• Convex-faced pharmaceutical tablets were theoretically analysed and optimised.

• Mathematical models of tabletting were designed using response surface methodology.

• The effects of geometrical parameters on compaction responses were evaluated.

• The optimal shape of the convex-faced tablets was determined.

Abstract

Capping failure, edge chipping, and non-uniform mechanical properties of convex-faced pharmaceutical tablets are common problems in the pharma industry. In this paper, the finite element method (FEM) and design of experiment techniques are used to determine the optimal shape of convex-faced (CF) pharmaceutical tablet which has more uniform mechanical properties and less capping and chipping tendency. The effects of different geometrical parameters and friction on the compaction responses of convex-faced pharmaceutical tablets were first identified and analysed. An FEM model of the tabletting process was generated using the implicit code ABAQUS and validated against experimental measurements. Response surface methodology was used to establish the relationship between the design variables, represented by the geometrical parameters and friction coefficient, and compaction responses of interest including residual die pressure, relative density variation within a tablet, and relative shear stress at the edge of a tablet. A statistical-based optimisation approach was then used to optimise the shape of CF tablets. The obtained results demonstrated how the geometrical parameters and friction coefficient of CF pharmaceutical tablets strongly affect their compaction behaviour and quality.

Graphical abstract

Keywords

Capping failure; Edge chipping; Tabletting; FEM; Optimisation; Residual radial pressure

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