OXFORD COLLEGE

PHARMACEUTICAL TECHNOLOGY

COMPRESSION MODULE

COMPRESSION – PRACTICAL WORKBOOK

Prepared by: Feroz Anjum

 Introduction to Compression Questions

Choose the correct answer and fill in the spaces:

compression and Consolidation - cohere to form a compact - compact –

reduction in volume - free flowing - Adhesion - of excellent compressibility -
mechanical strength

1- Compression is the --------------------- of a powder due to the application of a

stress.

2- Compaction is a general term used to describe the situation in which

powdered materials are subjected to some level of mechanical force. It may
be simply stated as ----------------------------------------------------- of a two - phase
(solid - gas) system due to the applied force.

3- Compactibility is the ability of a powder to cohere into a ----------- under

pressure.

4- Consolidation is an increase in the ----------------------------- of the material as a

result of
particle - particle interactions during compression.

5- For powders or granules to be made into tablets, three vital properties are
necessary:
----------------------------------, ----------------------------------
and---------------------------.

6- ----------------- of tablets to the punches and dies must be avoided, otherwise

damage to both the tablet and the machine may occur.
- Choose the correct answer and fill in the spaces:
Multiple Compressed Tablets, Lozenges, Chewable Tablets, Per-oral
tablets, Effervescent Tablets, Sublingual Tablets.

1. ---------------------------- are those intended to be

swallowed whole. They are designed to disintegrate
after swallowing.

2. -------------------- are designed to be kept in the

mouth and dissolve slowly in the buccal pouch.

3. ---------------------------------- are designed to rapidly

dissolve beneath the tongue. They produce an
immediate systemic effect by enabling the drug to
be directly absorbed through the mucosa e.g.
Nitroglycerine tablets.

4. ----------------------------------- are compressed tablets

designed to be chewed rather than swallowed and
slowly dissolve in the buccal pouch.

5. -------------------------------- are tablets formulated to

dissolve with effervescence when the tablet is
placed in water, with rapid release of active.

6. ---------------------------------- are tablets designed to

facilitate separation of incompatible ingredient(s)
and to produce repeat or prolonged release tablets.
It consists of several different granulations that are
 compressed on top of each other to form a single
tablet.

- How to evaluate material’s flowability? Mention the values.

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- Choose the correct answer and fill in the spaces
Sustained release (or prolonged action), Enteric coated or delayed
action,
sugar coating, film coating
a- Compressed tablets with an applied ----------------------- to mask
bitter, salty, or obnoxious taste or odor of a drug substance.

b- Compressed tablets with a -------------------------- applied. This

approach is economical and involves minimum exposure of the
tablet to heat and solvent(s).

c- ------------------------------------- tablets are coated to protect the drug

against decomposition in the stomach environment, and also for the
protection of the stomach from the irritating effect of the drug. These
tablets are designed to remain intact in the stomach then release
their active in the small intestine.
 d- ---------------------- Compressed tablets that are specifically
formulated to release the active drug over a prolonged period of
time. It consists of:

1- An immediately available dose that incorporated in the

tablet coating,

2- A sustaining portion in the core of the tablet

5- Mention advantages and disadvantages of oral route of administration .

Advantages Disadvantages

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6- Properties of tablets:

Choose the correct answer and fill in the spaces:

Uniformity, esthetic characteristics, disintegrate,

degradation,
The active ingredient, functional attributes, stable, abrasion

1. Sufficient strength and resistance to -----------------

in order to withstand the manufacturing process
 (handling, packaging, shipping, etc.) and at the
same time be capable of rapid breakdown in order
to release the drug rapidly.

2. Resistance to --------------------- during

manufacturing, however, the tablet must also
breakdown upon administration to ensure drug
availability.

3. ---------------- in weight, appearance, diameter and

active drug content.

4. Possession of favorable ------------------ as well as a

characteristic color(s), shape and/or other markings
by which the drug can be identified.

5. Retain all --------------------------- throughout all

processes (manufacturing, storage, and patient
handling) over a reasonable period of time (shelf
life).

6. When they are swallowed whole, they should

-------------- in the stomach.
This disintegration involves the bursting apart of
the compact by aqueous fluids penetrating
the fine residual pore structure of the tablet.

7. Dissolution of the drug from tablets into aqueous

fluids is a very important property of solid dosage
forms. ---------------------------- must be available
pharmacologically. It must first dissolve in the
gastric or intestinal fluids before absorption.
 8. Tablets should be ------------- to air, temperature,
light and moisture.

- Advantages of tablets:

Large-scale production, controlled, Adulteration, stable, Production

cost
Ease of shipment, convenient, uniform, identification markings, active

1. --------------------- of drug can be minimized and easy to discover.

2- Each tablet must contain a known amount of -------------- and this must be
checked
by “Dosage Uniformity test by weight variation” or “Content Uniformity
test”.

3- ---------------------- owing to their relatively lighter weight and compact

nature

4- It is easier to apply ------------------------------- or logos to tablets than to

other oral dosage forms, which requires additional processing steps.

5- Tablets offer a -------------------- means for patients who must take a drug,
particularly among those who routinely take multiple medications.

6- The release rate of the drug from a tablet can be ---------------- to meet
 pharmaceutical requirements.

7- Tablets are suitable for --------------------------------------

8- Tablets are more ----------------- than liquid preparations.

9- ----------------------- is very much lower than other dosage forms.

10- It is a -------------------- final product as regards weight and appearance

-Definition of tablets:

excipients – compaction – layered tablet-

solid – compression coated tablets

a- A compressed tablet is a ------------

dosage form that is prepared by ------------ of
a pharmaceutical formulation. This
formulation contains the active drug(s) and
-------------.

b- There are two classes of multiple

compressed tablets: -----------------------
--------------------- and
----------------------------------------------.
 Science of Compression Questions

Arrange the following processes in the correct order:

1- Compression ( )
2- Weight Adjustment ( )
3- Ejection ( )
4- Filling ( )

Arrange the following stages in the correct order:

5- Bonding ( )
2- Transitional repacking & Closer packing ( )
3- Viscous Flow & Microsquashing ( )
4- Fragmentation & Fracture ( )
5- Particle Deformation ( )
 True or False

6- Porosity will increase with deformation ( )

7- Volume will decrease with fragmentation ( )
8- Density will decrease with bonding formation ( )
9- Porosity will decrease with increasing the pressure ( )

True or False

1- Porosity = Void Volume x 100% ( )

Bulk Volume

2- Porosity = Bulk Volume – Tapped Volume x 100% ( )

Tapped Volume

3- Porosity = Tapped volume – Bulk Volume x 100% ( )

Bulk Volume

4- Porosity = Bulk Volume – Tapped Volume x 100% ( )

Bulk Volume

5- Porosity = Tapped density – Bulk density x 100% ( )

Tapped density

Mean Yield Stress is:

1- That stress beyond which permanent plastic deformation may occur (

)
 2- That stress beyond which fragmentation may occur ( )
3- That stress beyond which relaxation may occur ( )
4- That stress beyond which decompression may occur ( )

True or False

Lubrication Sensitivity Ratio (LSR) is:

1- CSU – CSL x 100 %

CSU ( )
2- CSL – CSU ( )
CSU
3- CSU – CSL x 100 % ( )
CSL
4- CSU – CSL ( )
CSU

If shape of particles changed permanently, after the “Yield Point”, we call it:

1. Plastically deformed ( )
2. Elastically deformed ( )
3. Fragmented ( )
- Brittle Fracture is:

5- Particles deform without fragmentation ( )

6- Particles fragment without deformation ( )
7- Particles fragment after deformation ( )

-Viscous Flow is happening with:

a. Elastically deformed materials ( )

b. Plastically deformed materials ( )
c. Crystalline materials ( )

- Microsquashing is happening with:

1. Elastically deformed materials ( )

2. Plastically deformed materials ( )
3. Crystalline materials ( )

- Crystalline materials are:

1. Hard materials ( )
2. Soft materials ( )
3. Deforming plastically to fill void spaces ( )
 4. Forming the strongest intermolecular bonds because their molecules
are aligned for interaction ( )

Amorphous materials are:

1. Hard materials ( )
2. Soft materials ( )
3. Deforming plastically to fill void spaces ( )
4. Fragmenting ( )

- We consider the powder is of excellent flow when:

1. Angle of repose is more than 50 degree ( )

2. Angle of repose is less than 25 degree ( )
3. Carr’s index is more than 20 % ( )
4. Carr’s index is less than 15 % ( )

Constant granulation density during compression process is important. Why?

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- Distinguish between elastic and plastic deformation

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Elastic material is desirable for tablet compression. Why? Discuss.

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Plastic deformation is desirable for tablet compression. Why? Discuss.
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Under high pressure:
 In some particles, -------------- deformation exists up to a point, known as the
–--------. Beyond this point, any further application of pressures may force a
permanent change in shape known as—------------------------ deformation.

 Elastic materials will deform --------------------------. If the pressure continued,

--------------------------- will occur forming -----------------------------.

 Brittle materials will ---------------------------without -----------------------------.

 Initially, crystalline materials will deform ----------------- then after the yield
point
-------------------------will occur.

 Initially, amorphous materials will deform -------------------

then after the yield point
------------------------------------------------will occur.

-Describe: “ Clean surfaces”.

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Describe:

 2 mechanisms of filling / feeding

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 2 mechanisms of Fusion bonding formation
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Causes of tablet weight variation:

 Lower punches length inconsistency ( )

 High speed of tablet press ( )
 High pressure of tablet press ( )
 Carr’s index is 30% ( )

Arrange the following types of bonding in the correct order,

the weakest
first:
a. Liquid surface film bonding ( )
b. Mechanical Interlocking ( )
c- Cold Welding (Intermolecular forces) ( )

- Optimum Moisture Content:

1. a. Helps in bonding formation ( )
2. b. If too high, it will interfere with intermolecular bonding ( )
3. c. If too low, will be insufficient solubilization of water soluble exipients ( )
4. d. All of the above ( )

- The main roles of mechanical interlocking:

a. To maintain the shape of elastic particles for other bonding mechanism to
occur. ( )
b. To maintain density of tablet during elastic recovery ( )
c. To make possibility of Van der waals bonding formation ( )
d. All of the above ( )

True or False
 a. Axial pressure is the force per unit area applied in the axial direction ( )
b. Radial pressure is the transmitted pressure in response to axial pressure ( )
c. Axial pressure is the transmitted pressure in response to radial pressure ( )
d. Radial pressure generates the shear that causes particle deformation ( )

- True or False

 a- Decompression is the pre-compression ( )

 Relaxation of tablet begins following decompression ( )
 Decompression occurs when the upper punch lifts off the
tablet ( )
 Relaxation of tablet continue for several hours or days after
compression ( )
 Relaxation of tablet stop after compression ( )
 If the rate of elastic recovery, in the axial direction, is fast,
tablet will split ( )
 The tablet may crack if the rate of relaxation along the
radial axis is slow ( )

- During decompression, is it desirable to have a tablet that undergoes fast or slow

elastic recovery? Why?

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- During decompression, is it desirable to have a tablet that

undergoes fast or slow plastic recovery? Why?

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- If a granulation were extremely dry, how will the properties of the resulting tablet be
affected?

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Compression Cycle:

Discuss factors affecting each process of compression cycle

Process Factors affecting it

1

4
 List at least 5 possible causes for tablets that weigh slightly less than the prescribed
weight, and explain briefly how each can contribute to this problem.

a.
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b.
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c.
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d.
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e.
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- Heckel Plot is:

1. The relationship between pressure and volume ( )

2. The relationship between density and volume ( )
3. The relationship between pressure and porosity ( )
4. The relationship between porosity and volume ( )

- Heckel plots:

1. Provide information about fragmentation of particles during compression ( )

2. Provide information about deformation of particles during compression ( )
3. Provide information about porosity of the materials ( )
4. Help predict the compressibility of a formulation ( )
5. All of the above

- What would happen if there were a large proportion of fines in your granulation?
How to troubleshoot?
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- Distinguish between adhesion and cohesion. Provide examples.

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- Heckel plots:

- Distinguish between glidant and an antiadherent. Provide examples.

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During tablet compression, specific surface area increases due to:

1. Transitional repacking ( )
2. Fragmentation ( )
3. Bonding formation ( )
4. Tablet relaxation ( )

Energy is required to eject the tablet from the die cavity. This energy must
overcome:

1. Bonding formed between the tablet and die wall ( )

2. Residual radial pressure exerted by the tablet on the die wall ( )
3. Frictional forces between the tablet surface and the die wall ( )
4. All of the above ( )

- Compression dwell time is:

1. The length of time the tablet press forming a tablet ( )

2. The length of time the upper and lower punches are inside the die cavity (
)
3. The length of time the upper and lower punches are compressing the
granules ( )

- Fill in the spaces:

 Perfectly elastic body - Mohr body - plastic deformation

1- A tablet may behave as a -----------------------if after the elastic limit has been
reached
fragmentation occurs. As the elastic recovery pushes the particles away from
each other;
it creates void spaces within the tablet that may result in
--------------------------.

2- If the tablet were ---------------------------------- the amount of axial pressure will

be equal to
the resulting radial pressure.

3- In case of typical tablets, after the elastic limit has been reached,
---------------------- occurs.

- For better compressibility characteristics, formulation should be:

a- ------------------------------------------------------------------------------------------
------------
b-
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- The crystallinity of excipients is important in determining their capacity for

--------------------

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How to troubleshoot capping and lamination due to fast elastic recovery?

1-
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2-
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--------

- what is the importance of tablet porosity?

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Fill in the space:

direct compression, intermolecular bonds, crystallinity

amorphous particles, crystalline particles, interaction

1- Crystalline materials form the strongest -------------------------------because

their molecules are aligned for -------------------. Therefore, the ---------------------------

of excipients, in addition to their deformation or fragmentation characteristics

is important in determining their capacity for -----------------------------------.

2- Directly compressible excipients are usually crystalline or contain a large

proportion of crystallites embedded within an amorphous region.

The ---------------------------------deform plastically to fill the void spaces and to

relieve
stresses during compression, while the -------------------------------provide surfaces
for the
creation of strong intermolecular bonds.

Compression Machinery Questions

Choose the correct answer and fill in the spaces:

Research and development - die table – punches – feeding – guides - take-off bar-
Die filling – volumetrically – Compression - single punch press – Ejection - rotary
punch press – holding – tablet - scrape-off bar - the speed, weight adjustment

 All tablet presses perform the same basic operating cycle during which
------------,
-------------------, ------------------- and -------------------- occur.
 Because die filling is done ---------------------, meaning that a specific volume of
material is introduced into the die cavity, it is important that an accurate volume
of fill material enter the die cavity every time.

 There are two types of tablet presses: ------------------------- and

-----------------------

 A single station press uses a single die and one pair of punches. It is used
primarily for ----------------------------------------.

 The dies are set in a rotating disc, called a ----------------------, while the punches
are set in tracks mounted above and below the table.

 The table and tracks rotate together, so that one die is always associated with one
pair of -----------------.

 The hopper is used for ----------------- and --------------- granules or powder into
the tablet press.

Choose the correct answer and fill in the spaces:

 The shape and size of the die cavity determines the size and shape of the
----------.

 The feed frame --------------- the powder or granulation from the hopper into the
die cavity by spreading the material over the die table. It is a stationary
component and consists of a ------------------------, which removes excess material
from the top of the die table, the ----------------------, which directs the tablets off
of the die table, and stud and lock nuts for holding the feed frame in position.
  Dwell time is the time the punches remain in the die compressing tablets. It
depends on ------------------- that the press is rotating. Greater dwell time
generates stronger bonds between
granules and allowing potential stresses to relax.

Choose the suitable feeding system: (Induced feeding system / gravity

feeding
mechanism):

 It is difficult to fill small die cavities uniformly at high press speed.

Uniformity can be improved using --------------------------------------------.This
will force the granulation into the die and are always necessary for high-speed
presses.

 If flowability of granulation is poor and the press is operating at high speed,

less material will enter die cavity. --------------------------------- should be used.

 If flowability of the granulation is good and the press is operating at slower

speed use -----------------------------------.

 If you have tablet weight variation, ----------------------------------is preferred.

Answer the following:

 What are the components of single punch press? For what purpose is it used?

 Compression Machines are made with GMP Consideration.

Explain.

 Feed Frame is an important part of tablet press. Describe

its parts and their functions.
How to install it and what precautions must be done?
 How to adjust the machine to produce exact tablet weight?
Which part of the machine you would use?

 How to lubricate tablet press after tablet compression?

Which parts you lubricate with mineral oil?

 How to prevent contamination and cross contamination

during tablet production?

 If a 12 – station press (in a single raw) can produce 50,000

tablets / hour, how fast does the die table turn? (The
answer is 69.44 RPM)

 You have 10 Kg of lubricated granules. You must compress

the granules in a
24-station tablet press that operates at 400 RPM. If the
weight of each tablet is
250 mg. How long would it take to compress the batch?
(The answer is: 4.16 min)

True or False:

 In a rotary tablet press, the hopper is used for:

 a. controlling the motion of the upper punch ( )
b. holding and feeding material into the tablet press ( )
c. guiding the material into the die cavity ( )

 In a compression machine, the turrets:

a) hold the die and the die lock screws ( )

b) raise the lower punch to eject the tablet ( )
c) hold the upper and lower punches ( )

 In a compression machine, the compression roll:

a) guides the material into the die cavity for compression ( )

b) drives the upper and lower punches into the die cavity ( )
c) locks the die into the die table ( )
d) varies the speed of the compression cycle ( )

Tooling Questions
 Fill in the spaces:

1- The basic unit of any tablet press is the -----------, which consists of
two ---------------- and a ---------, are referred to as a -----------------------.

2- The stem of the lower punch is --------------- than that of the upper punch, which
allows it to rise up through die and eject the tablet following compression.
(Longer/ shorter).

3- ------------------length is the total length of the punch from end to end.

(Overall / Working)

4- ----------------length is the length of the punch from the bottom of the cup to the
head flat. (Overall / Working)

Choose the correct type of tooling: B, B2, or D

1- Upper punch (5 ¼ inches) is longer than lower punch (3 9/16 inches)

2- ( )
2- Upper and lower punches of the same overall length (5 ¼ inches) ( )
3- Head diameter is (1 ¼ inches) ( )
4- Barrel diameter is (1 inch) ( )
5- Upper and lower punches of same barrel diameter (3/4
inches) ( )
6- Upper and lower punches of same head diameter (1 inch) ( )
7- Produce more massive, making larger and stronger tablets ( )

To lubricate tooling before use, you should lubricate all parts,

Except:

1. The head, the tip and the stem ( )

2. The head, the barrel and the stem ( )
3. The stem, the tip and the punch face ( )
4. The neck, the head and the tip ( )

- Prior to storage, tooling must be removed from the tablet press then:

1- Stored, cleaned and then lubricated before

next use ( )
 2- Cleaned, lubricated and then stored
( )
3- Cleaned, stored and lubricated before next
use ( )
4- Lubricated to prevent rust formation then
stored ( )

True or False:

a- The lower punch is equipped with a hardened tip that absorbs the tremendous
pressure
exerted upon it by the upper punch during compression. ( )

b-The lower shaped punch requires a key to secure it in its position during
compression ( )

c- Particle hardness is a factor that contribute to the rate and extent of tooling
wear. ( )

d- The tooling card contains information about the person used the tooling ( )

e- The tooling usage log contains information about tooling and tablet press ( )

True or False:
With type B tooling:
a) the upper and lower punches are of same length ( )
b) the upper punch is longer than the lower punch ( )
c) the lower punch is longer than the upper punch ( )
d) the punch barrel is one inch in diameter ( )
e) the stem of both punches are of same length ( )

When handling tooling, it is important that:

f) tooling be lubricated prior to being placed in storage ( )
g) tooling be lubricated prior to being installed in the tablet press ( )
h) tooling be stored in protective sleeves when not in use ( )
i) all of the above ( )

The rate and extent of tooling wear is not affected by:

j) the hardness of the particles being compressed ( )
k) the density of the particles being compressed ( )
l) the shape of the particles being compressed ( )
m) the pressure at which particles are being compressed ( )
The main reasons for tooling failure are:
n) the granules are too hard to compress ( )
o) insufficient moisture in the granulation ( )
p) excessive pressure used during compression ( )
q) all of the above ( )

The tooling card contains information about:

r) the machine type the tooling is used in ( )
s) the tooling shape ( )
t) the number of tablets produced with the tooling ( )
u) the signature of the person using the tooling ( )

The stem of the lower punch is longer than the stem of the upper punch:
v) so that it can eject the tablet from the die ( )
w) so that it can withstand more compression force ( )
x) so that it can exert more pressure on the material within the die ( )
y) all of the above ( )

. Tip relief is:

1. The recessed portion of the neck with the head. ( )
2. The angle between stem and the barrel ( )
3. The angle between stem and punch face ( )
4. The recessed portion of the tip into the stem ( )

Calculations:

1- Bulk density of 0.505 g / cm3. Weight of a tablet is: 820 mg

- Calculate the range of thickness assuming 50 % to 80 % reduction
 - Caplet: 19 mm x 8 mm

2- Bulk density of 0.611 g / cm3. Weight of a tablet is: 600 mg

- Calculate the range of thickness assuming 50 % to 80 % reduction
- Oval: 19 mm x 11 mm

3- How to select tooling to make round tablets of 650 mg tablet weight and bulk
density
of 0.72 g/cm3. Assuming 70 % reduction. Thickness is 0.32 cm

4- How to select tooling to make round tablets of 300 mg tablet weight and bulk
density
of 0.51 g/cm3. Assuming 50 % - 80 % volume reduction. Thickness is 0.30 cm