Optimization of continuous manufacturing process for direct compression of vitamin tablets
The purpose of this study is to optimize the process of vitamin tablets using a direct compression continuous manufacturing(CM). Compared to the batch manufacturing process, the CM offers advantages such as reduced production time and cost efficiency. However, several critical challenges must be solved for successful implementation. In particular, predicting the material emission amount per revolution of the twin screw is challenging, making it difficult to establish the appropriate screw speed (rpm). When the feed rate falls below the minimum threshold, the emission amount becomes inconsistent, leading to potential content uniformity issues. To solve these challenges, we conducted a feeder factor study and a study of minimum supply. In the feeder factor study, we measured the discharge rate at different twin screw rotation speeds, generating data that enabled the determination of the optimal rpm. In the study of minimum supply, we identified the lowest input mass to ensure a consistent emission amount. As a result, we established the optimal feeder operating conditions to maintain stable emission amount in the continuous manufacturing process. Experiments conducted under these conditions showed that vitamin content consistently ranged between 90% and 150%. This study confirms the feasibility of practical application for continuous direct compression manufacturing.
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