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Innovative-Process-Applications/ipa-pharma-compactor-platform

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… See the full description on the dataset page: https://huggingface.co/datasets/Innovative-Process-Applications/ipa-pharma-compactor-platform.

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Dataset Card

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.

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

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

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

1.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