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Powder compaction is widely used in pharma to produce pharmaceutical tablets and it is referred to as a tabletting process. Tabletting consists of three main stages: (1) die filling, where a mixture of pharmaceutical powders are delivered into the die cavity via a feed shoe; (2) compaction, where the powder is pressed inside a die by two punches to produce the tablet; and (3) ejection, where the tablet is ejected from the die by the lower punch. The powder behavior during each of these stages has an effect on the properties of final tablet [1].
Despite wide adoption of tabletting process, obtaining a high-quality pharmaceutical compact continues to remain a significant challenge in practice as many complex interactions occur during the process and lead to many undesirable defects. Solving the main problems in tabletting necessitates a science-based approach that could help in establishing the comprehensive understanding of material behavior and the failure causes. Due to complex and nonlinearity nature of the tabletting process, the tabletting problem cannot be solved analytically without major simplifications and thus empirical methods, such as Heckel analysis and Kawakita equation, have been used extensively to analyze the compaction process. However, the empirical techniques only consider the punch forces for assessing the tablet properties and cannot describe the main mechanisms of main tabletting issues. Recently, computational modeling has emerged as a powerful tool for attaining a new insight into the tabletting process.
Computational modeling of the tabletting process is a very useful, effective and robustness technique that generates essential information about compact density, elastic deformation during ejection and the strength of the final product.
Moreover, tabletting process simulation can reduce material and development costs, enhance quality, and shorten time-to-market through virtual prototyping and optimization. Also, the numerical simulations enable innovation through its unique numerical visualization tools which offer a wealth of detailed information, not always readily available from experimental tests.
This article aims to present an overview of the main topics in the area of mechanics and computational modeling of pharmaceutical tabletting process. The focus of this article is on the finite element modeling approach as it is more suitable for solving the engineering problems of the tabletting process.
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