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

1---2license: cc-by-4.03language:4  - en5pretty_name: "IPA Pharmaceutical Roller Compactor Platform: Scale-Up & Performance (Synthetic)"6size_categories:7  - 1K<n<10K8task_categories:9  - tabular-regression10tags:11  - roller-compaction12  - pharmaceutical-manufacturing13  - dry-granulation14  - scale-up15  - quality-by-design16  - twin-feed-screw17  - process-engineering18  - synthetic-data19  - education20configs:21  - config_name: default22    data_files:23      - split: train24        path: "ipa_pharma_compactor_v1.0.csv"25---26 27 28# IPA Pharmaceutical Roller Compactor Platform: Scale-Up & Performance (Synthetic)29 30**Version:** 1.031**Publisher:** [Innovative Process Applications (IPA)](https://www.innovativeprocess.com)32**License:** Creative Commons Attribution 4.0 International (CC BY 4.0)33 34> ⚠️ **This dataset is 100% synthetic and intended for educational use only.**35> Generated from IPA's published CL-series specifications and standard36> compaction physics — not real production or clinical batch data.37 38---39 40## What's in this dataset41 423,000 simulated pharmaceutical roller compaction runs spanning IPA's complete43CL-series platform — from R&D lab (CL25150, 5 HP) through full production44(CL100250, 25 HP) — across 5 pharma/nutraceutical materials and the full45operating envelope of twin-feed-screw process parameters.46 47### Equipment specifications (from IPA published data)48 49| Model | Roll Size | Max Pressure | Integrated Mill | Power | Scale |50|---|---|---|---|---|---|51| CL25150 | 1"×6" (2.5×15 cm) | 17.5 kN/cm | None | 5 HP | R&D / Lab |52| CL30200 | 1"×8" (3×20 cm) | 17.5 kN/cm | PM3 | 2.75 HP | Pilot |53| CL50200 | 2"×8" (5×20 cm) | 26.0 kN/cm | PM6 | 12 HP | Pilot / Small Prod |54| CL75200 | 3"×8" (7.5×20 cm) | 15.0 kN/cm | PM6 | 20 HP | Production |55| CL100250 | 4"×10" (10×25 cm) | 17.5 kN/cm | PM8 | 25 HP | Full Production |56 57### Column descriptions58 59| Column | Units | Description |60|---|---|---|61| `compactor_model` | — | IPA CL-series model |62| `scale` | — | R&D / Lab, Pilot, Production, Full Production |63| `roll_diameter_in` / `_cm` | in / cm | Roll diameter |64| `roll_width_in` / `_cm` | in / cm | Roll width |65| `max_roll_pressure_kn_cm` | kN/cm | Maximum specific compaction force |66| `integrated_mill` | — | PM-series in-air impact mill (or None) |67| `total_power_kw` | kW | Total system power |68| `material` | — | Pharma material identifier |69| `feed_density_gcc` | g/cc | Feed powder bulk density |70| `deformation_type` | — | Plastic, brittle, or mixed |71| `roll_pressure_fraction` | — | Fraction of max pressure applied (0.3–1.0) |72| `scf_kn_cm` | kN/cm | Actual specific compaction force |73| `roll_speed_rpm` | rpm | Roll rotation speed |74| `hfs_speed_rpm` | rpm | Horizontal feed screw speed (controls throughput) |75| `vfs_hfs_ratio` | — | Vertical/horizontal feed screw speed ratio (controls pre-compression) |76| `gap_width_mm` | mm | Roll gap |77| `ribbon_rel_density` | — | Relative density (fraction of true density) |78| `ribbon_density_gcc` | g/cc | Absolute ribbon density |79| `ribbon_porosity` | — | 1 − relative density |80| `density_cv_pct` | % | Across-ribbon density uniformity |81| `fines_pct` | % | Fines fraction after milling |82| `granule_yield_pct` | % | Usable granule yield |83| `in_zinchuk_window` | Yes/No | Ribbon RD in 0.60–0.80 tabletability range |84| `throughput_kg_hr` / `_lbs_hr` | kg/hr / lbs/hr | Mass throughput |85| `specific_energy_kwh_tonne` | kWh/tonne | Energy efficiency |86| `changeover_time_hr` | hours | Estimated changeover time |87 88## IPA platform advantages demonstrated in the data89 901. **Twin feed screw (HFS + VFS):** Independent control of throughput (HFS)91   and pre-compression (VFS) produces a uniquely tunable operating space.92   The VFS/HFS ratio is a key process parameter not available on single-screw93   compactors.94 952. **Scalable platform:** Consistent ribbon quality (CV%, yield) across the96   CL25150 → CL100250 range, enabling direct R&D-to-production scale-up.97 983. **Integrated in-air impact milling:** PM-series mills minimize heat99   generation and maximize granule yield with precise PSD control.100 1014. **Efficient changeover:** Modular design enables fast product changeover,102   critical for multi-product pharma facilities.103 1045. **Low bulk density capability:** Twin screw design is proven efficient105   with light powders (feed density 0.3–0.5 g/cc) containing high air content.106 107## Cross-links108 109- **Kaggle:** [link after publication]110- **Hugging Face:** [link after publication]111- **Zenodo:** [link after publication]112- **GitHub:** [link after publication]113- **IPA website:** https://www.innovativeprocess.com114 115## Citation116 117> Innovative Process Applications (2026). *IPA Pharmaceutical Roller Compactor118> Platform: Scale-Up & Performance (Synthetic), v1.0*. CC BY 4.0.119> https://www.innovativeprocess.com120