Enhancing Tablet Manufacturing Efficiency Through Numerical Simulation and Modeling of Pharmaceutical Powder Compaction: A Comprehensive Review

Pharmaceutical powder compaction is a crucial process in tablet production that offers numerous benefits, including efficient production, consistency, cost-effectiveness, and enhanced tablet properties. It also has some limitations that must be considered. One limitation is that the compaction process can lead to the formation of defects in the tablets, such as cracks, splits, or capping, which can affect the mechanical strength, dissolution rate, and stability of the tablet. The use of numerical simulation can be relied upon to identify and fix these limitations by providing a cost-effective and efficient means of optimizing the compaction process and predicting the quality and properties of the final product. Tablet production involves various factors specific to the powders used, such as their coefficient of friction, mechanical behavior, and modulus of elasticity. Die compaction of the powder mixture causes a decrease in volume due to elastic and plastic deformations sustained by the particles. Elasto-plastic behavior is the most commonly considered densification mechanism. Numerical simulation plays a significant role in optimizing the manufacturing process. There are two main approaches to modelling compact compression: discrete and continuous. Several simulation models have been developed using both approaches. This article introduces the various modelling methods developed so far, highlighting their principles, approaches, advantages, and limitations to provide a solid starting point for researchers in the field.