Uniformity Differentiation Analysis of Powder Deposition Characteristics in Circular and Rectangular Shallow Dies Using Feed Shoe with Square Cross-Section

Abstract

The inhomogeneity of the pressure distribution after completion of the filling process might create tablet and compact quality issues. Generating a uniform precompaction powder deposition into a die would minimize one source of tablet quality issues. This article determines the characteristics of the deposition process into a rectangular die and a circular shallow die, using a feed shoe with a square cross-section tube. A series of experiments were performed that determined the cumulative influence of particle size, die geometry, and feed shoe speed on uniformity of pressure distribution at the end of filling process. For uniformity comparison, the profiles of pressure distribution at the end of filling process were displayed as contour plots. Symmetry analysis, variance metrics, and uniformity analysis were implemented to quantify the deposition characteristics. Feed shoe speeds of 20 and 100 mm/s were used to fill the die. Due to their differing particle characteristics and importance, a pharmaceutical powder filler (microcrystalline cellulose-Avicel PH102) and a battery powder mixture (BPM) were used as test materials. The results showed that (1) contour plot was the most reliable method for evaluating uniformity deposition characteristics in dies; (2) based on contour plot analysis, BPM deposition at 100 mm/s feed shoe speed for circular shallow dies resulted in the most uniform pressure distribution among all, that is, 64% uniformity at ±20 dm (decimeter) resolution and 14.7% coefficient of variation (COV); (3) Avicel deposition at 20 mm/s feed shoe speed for circular dies had the least uniformity (46%); (4) rectangular dies generally had lower symmetry index (61%) in comparison with circular dies, which was attributed to sharp edges of rectangular die, that is, particles trapped in corners generated higher stresses inside the rectangular die versus circular die.