Predicting powder flow within the tablet press feed frame is challenging, but Discrete Element Method (DEM) simulations provide valuable insights into internal flow dynamics. This study employs DEM to analyze particle behavior within the XL-100 feed frame, with a specific focus on particles inside the die, referred to as tablet particles. Simulations were performed using both free-flowing and cohesive powders under three different paddle and turret speed conditions.
Under gravity filling conditions, the study examined tablet particle residence time distribution and size-based segregation within the die. For free-flowing powders, size-based segregation was observed. Additionally, significant variations in residence time distribution were noted across different paddle and turret speeds, although the average residence time can remain largely unchanged.
The findings suggest that average residence time alone is insufficient for assessing powder behavior. Instead, residence time distribution serves as a more effective indicator for predicting excessive tablet lubrication, which can impact final tablet properties.