The ability to use bench-scale compression/uniaxial stress to simulate the results and target process conditions for kilo-scale roller compaction/shear stress is useful and economically advantageous. A calibrated roller compaction model with an analytical solution to Johanson’s theory is utilized, with input parameters derived from bench-scale STYL’One compaction simulator data. This work focuses on understanding the bias function in predicting roll force as a function of key inputs, including both in-die and out-of-die derived Compressibility Factor (K) and material pre-consolidation (ϒo).

Results:

Results indicate that the bias in predicted roll force for a targeted ribbon solid fraction changes linearly with K (typically, 3–7) but shifting from underestimation of roll force for K<3.4 to overestimation.

Conclusion:

The approach of using the Compressibility Factor may expedite scaleup to kilo-scale roller compaction with material-sparing use of compaction simulator technology and secondary analysis.