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ipa-pharma-compactor-platform

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roller-compaction
pharmaceutical-manufacturing
dry-granulation
scale-up
quality-by-design
twin-feed-screw
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metadata 
license: cc-by-4.0
language:
  - en
pretty_name: >-
  IPA Pharmaceutical Roller Compactor Platform: Scale-Up & Performance
  (Synthetic)
size_categories:
  - 1K<n<10K
task_categories:
  - tabular-regression
tags:
  - roller-compaction
  - pharmaceutical-manufacturing
  - dry-granulation
  - scale-up
  - quality-by-design
  - twin-feed-screw
  - process-engineering
  - synthetic-data
  - education
configs:
  - config_name: default
    data_files:
      - split: train
        path: ipa_pharma_compactor_v1.0.csv

IPA Pharmaceutical Roller Compactor Platform: Scale-Up & Performance (Synthetic)

Version: 1.0 Publisher: Innovative Process Applications (IPA) License: Creative Commons Attribution 4.0 International (CC BY 4.0)

⚠️ This dataset is 100% synthetic and intended for educational use only. Generated from IPA's published CL-series specifications and standard compaction physics — not real production or clinical batch data.

What's in this dataset

3,000 simulated pharmaceutical roller compaction runs spanning IPA's complete CL-series platform — from R&D lab (CL25150, 5 HP) through full production (CL100250, 25 HP) — across 5 pharma/nutraceutical materials and the full operating envelope of twin-feed-screw process parameters.

Equipment specifications (from IPA published data)

Model Roll Size Max Pressure Integrated Mill Power Scale
CL25150 1"×6" (2.5×15 cm) 17.5 kN/cm None 5 HP R&D / Lab
CL30200 1"×8" (3×20 cm) 17.5 kN/cm PM3 2.75 HP Pilot
CL50200 2"×8" (5×20 cm) 26.0 kN/cm PM6 12 HP Pilot / Small Prod
CL75200 3"×8" (7.5×20 cm) 15.0 kN/cm PM6 20 HP Production
CL100250 4"×10" (10×25 cm) 17.5 kN/cm PM8 25 HP Full Production

Column descriptions

Column Units Description
compactor_model — IPA CL-series model
scale — R&D / Lab, Pilot, Production, Full Production
roll_diameter_in / _cm in / cm Roll diameter
roll_width_in / _cm in / cm Roll width
max_roll_pressure_kn_cm kN/cm Maximum specific compaction force
integrated_mill — PM-series in-air impact mill (or None)
total_power_kw kW Total system power
material — Pharma material identifier
feed_density_gcc g/cc Feed powder bulk density
deformation_type — Plastic, brittle, or mixed
roll_pressure_fraction — Fraction of max pressure applied (0.3–1.0)
scf_kn_cm kN/cm Actual specific compaction force
roll_speed_rpm rpm Roll rotation speed
hfs_speed_rpm rpm Horizontal feed screw speed (controls throughput)
vfs_hfs_ratio — Vertical/horizontal feed screw speed ratio (controls pre-compression)
gap_width_mm mm Roll gap
ribbon_rel_density — Relative density (fraction of true density)
ribbon_density_gcc g/cc Absolute ribbon density
ribbon_porosity — 1 − relative density
density_cv_pct % Across-ribbon density uniformity
fines_pct % Fines fraction after milling
granule_yield_pct % Usable granule yield
in_zinchuk_window Yes/No Ribbon RD in 0.60–0.80 tabletability range
throughput_kg_hr / _lbs_hr kg/hr / lbs/hr Mass throughput
specific_energy_kwh_tonne kWh/tonne Energy efficiency
changeover_time_hr hours Estimated changeover time

IPA platform advantages demonstrated in the data

  1. Twin feed screw (HFS + VFS): Independent control of throughput (HFS) and pre-compression (VFS) produces a uniquely tunable operating space. The VFS/HFS ratio is a key process parameter not available on single-screw compactors.

  2. Scalable platform: Consistent ribbon quality (CV%, yield) across the CL25150 → CL100250 range, enabling direct R&D-to-production scale-up.

  3. Integrated in-air impact milling: PM-series mills minimize heat generation and maximize granule yield with precise PSD control.

  4. Efficient changeover: Modular design enables fast product changeover, critical for multi-product pharma facilities.

  5. Low bulk density capability: Twin screw design is proven efficient with light powders (feed density 0.3–0.5 g/cc) containing high air content.

Cross-links

  • Kaggle: [link after publication]
  • Hugging Face: [link after publication]
  • Zenodo: [link after publication]
  • GitHub: [link after publication]
  • IPA website: https://www.innovativeprocess.com

Citation

Innovative Process Applications (2026). IPA Pharmaceutical Roller Compactor Platform: Scale-Up & Performance (Synthetic), v1.0. CC BY 4.0. https://www.innovativeprocess.com