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roller-compaction-ribbon-density

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roller-compaction
pharmaceutical-manufacturing
design-of-experiments
response-surface-methodology
quality-by-design
synthetic-data
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run_id
int64
1
600
roll_force_kN_per_cm
float64
2.07
14
roll_speed_rpm
float64
1.01
12
feed_screw_rpm
float64
10.1
120
roll_gap_mm
float64
1.5
4.5
peak_pressure_MPa
float64
8.3
88.3
ribbon_rel_density
float64
0.45
0.89
ribbon_density_g_cc
float64
0.7
1.39
ribbon_porosity
float64
0.11
0.55
density_CV_percent
float64
1.02
7.39
throughput_kg_hr
float64
3.35
155
1
11.29
6.25
72.3
3.33
50.5
0.7925
1.2284
0.2075
1.55
64.12
2
7.27
9.38
70.6
3.37
32.3
0.6925
1.0734
0.3075
2.99
84.72
3
12.3
10.94
101.1
1.91
72.8
0.8489
1.3159
0.1511
2.07
71.47
4
10.37
8.93
88.2
3.58
44.7
0.7605
1.1788
0.2395
1.07
93.54
5
3.13
11.6
12.9
3.52
13.6
0.4967
0.7699
0.5033
4.49
81.62
6
13.71
9.6
15.4
3.55
59.4
0.6962
1.0791
0.3038
4.77
93.36
7
11.13
10.53
76.2
1.72
69.3
0.8249
1.2786
0.1751
3.02
58.84
8
11.43
2.26
63.5
2.84
55.4
0.6882
1.0666
0.3118
6.47
18.04
9
3.54
9.06
38.6
2.73
17.5
0.5829
0.9035
0.4171
4.18
57.77
10
7.4
5.84
56.1
1.76
45.6
0.7836
1.2146
0.2164
2.9
30.6
11
6.45
7.08
93.4
2.17
35.8
0.7341
1.1379
0.2659
1.78
45.62
12
13.12
8.2
100.9
2.82
63.8
0.8114
1.2576
0.1886
2.1
74.36
13
9.73
11.67
71.7
3.73
41.1
0.707
1.0959
0.293
3.38
119.7
14
11.87
11.83
52.4
2.21
65.2
0.7844
1.2159
0.2156
3.74
80.85
15
7.32
4.17
39.8
3.99
29.9
0.7211
1.1177
0.2789
2.14
49.49
16
4.73
9.07
67.4
3.14
21.8
0.6433
0.9971
0.3567
2.09
74.88
17
8.66
9.25
44.6
3.78
36.3
0.6927
1.0737
0.3073
4.41
96.84
18
2.77
4.81
72.1
2.92
13.2
0.5531
0.8574
0.4469
2.61
28.91
19
11.93
2.36
84.4
3
56.3
0.6707
1.0396
0.3293
7.31
19.51
20
9.58
1.45
17.3
3.36
42.7
0.761
1.1796
0.239
2.04
15.93
21
11.1
9.55
10.1
4.28
43.8
0.6543
1.0141
0.3457
5.77
106.89
22
6.25
6.39
33.4
2.98
29.6
0.6426
0.996
0.3574
3.65
49.44
23
13.65
11.84
108.4
3.09
63.4
0.8208
1.2723
0.1792
2.2
119.09
24
12.72
6.11
81.1
3.31
57.1
0.8231
1.2759
0.1769
2.08
65.66
25
11.34
11.76
28.9
3.71
48.1
0.6943
1.0761
0.3057
4.91
118.87
26
4.34
5.53
107.9
1.72
27
0.5689
0.8818
0.4311
4.99
18.47
27
7.6
9.73
61.7
3.05
35.6
0.6959
1.0787
0.3041
2.86
82.06
28
2.53
1.93
62.4
2.94
12
0.4714
0.7306
0.5286
6.44
10.88
29
3.85
7.11
112.9
4.27
15.2
0.5667
0.8784
0.4333
3.02
68.76
30
10.2
9.82
16.5
2.98
48.2
0.6915
1.0719
0.3085
6.07
78.02
31
10.94
11.17
33.7
2.9
52.4
0.7167
1.1109
0.2833
4.61
92.9
32
13.61
10.05
74.4
4.39
53.1
0.7853
1.2173
0.2147
3.36
139.9
33
5.91
1.41
31.5
2.85
28.6
0.5704
0.8841
0.4296
5.68
9.16
34
6.45
5.1
84.7
2.04
36.8
0.6765
1.0486
0.3235
3.7
27.76
35
7.63
1.54
33.6
2.15
42.5
0.6695
1.0376
0.3305
5.09
9.2
36
4.27
2.2
20.9
1.79
26.1
0.6515
1.0098
0.3485
1.96
13.17
37
3.56
8.43
32.8
1.5
23.7
0.5757
0.8923
0.4243
4.36
27.26
38
7.71
8.85
56.5
2.8
37.6
0.7089
1.0988
0.2911
3.79
69.6
39
4.72
9.51
29.4
3.81
19.8
0.5856
0.9078
0.4144
4.7
82.63
40
10.04
10.52
24.8
3.7
42.6
0.6768
1.0491
0.3232
5.46
103.32
41
7.25
9.13
104.6
1.6
46.8
0.7387
1.1449
0.2613
2.27
42.5
42
11.99
9.81
45.2
3.21
54.7
0.7576
1.1743
0.2424
4.6
96.31
43
10.4
1.54
49.7
1.96
60.6
0.6718
1.0413
0.3282
6.47
10.72
44
5.75
3.58
16.1
4.32
22.6
0.6035
0.9354
0.3965
4.96
37.59
45
11.99
7.84
49.3
2
69.2
0.7982
1.2372
0.2018
3
48.96
46
11.66
10.44
39.1
3.38
51.8
0.7095
1.0997
0.2905
4.03
102.68
47
6.65
1.05
77.2
2.48
34.5
0.5976
0.9262
0.4024
6.02
5.5
48
5.46
6.66
32.6
3.42
24.1
0.6091
0.9441
0.3909
4.75
54.06
49
10.19
8.45
107.7
2.74
50.3
0.7679
1.1902
0.2321
2.51
67.53
50
3.68
1.33
112.3
3.78
15.4
0.5126
0.7945
0.4874
6.37
12.24
51
4.4
5.41
21
2.19
24.3
0.5962
0.9241
0.4038
4.78
29.42
52
2.09
10.85
21.8
4.22
8.3
0.4971
0.7706
0.5029
5.31
93.55
53
11.44
8.39
22.7
3
53.9
0.727
1.1268
0.273
5.56
70.23
54
9.98
3.61
78.2
3.77
42
0.6481
1.0046
0.3519
4.94
37.08
55
10.46
10.38
23.4
4.05
42.5
0.6629
1.0275
0.3371
4.84
110.24
56
11.37
4.83
103.8
4.5
43.8
0.6419
0.995
0.3581
5.34
56.29
57
7.51
10.39
93
2.17
41.6
0.7436
1.1525
0.2564
1.47
63.83
58
8.82
4.29
100.2
2.36
46.9
0.6619
1.026
0.3381
6.39
28.69
59
3.68
7.49
67.9
2.25
20
0.5844
0.9058
0.4156
2.12
40.15
60
3.37
5.37
119.6
2.29
18.2
0.5281
0.8186
0.4719
6.03
25.58
61
10.02
4.02
14.9
3.25
45.4
0.689
1.068
0.311
5.3
36.55
62
7.65
10.75
54.1
4.48
29.5
0.6674
1.0345
0.3326
3.61
125.94
63
8.78
3.06
45.6
4.47
33.9
0.6621
1.0263
0.3379
2.69
34.98
64
11.18
1.93
114.4
3.08
52
0.6491
1.0061
0.3509
6.55
14.58
65
9.62
4.76
73.5
3.42
42.5
0.7394
1.1461
0.2606
3.47
44.77
66
8.64
8.89
98.7
4.08
34.9
0.7335
1.1369
0.2665
1.77
106.5
67
8.71
9.88
28.7
4.3
34.3
0.6351
0.9844
0.3649
4.44
108.42
68
5.65
11.99
117.6
2.11
31.7
0.6846
1.0612
0.3154
2.51
67.44
69
2.37
4.26
64.9
3.09
11
0.5497
0.852
0.4503
3.14
29.08
70
7.24
5.49
64.3
4
29.6
0.6484
1.005
0.3516
1.21
55.83
71
4.58
2.51
116.8
2.41
24.1
0.5256
0.8146
0.4744
6.01
13.03
72
6.9
7.32
51.9
2.82
33.6
0.6815
1.0563
0.3185
3.46
54.67
73
12.24
11.97
53.7
4.46
47.3
0.7424
1.1507
0.2576
4.16
155.25
74
4.81
8.71
74.3
4.46
18.6
0.6011
0.9317
0.3989
2.06
93.76
75
2.7
7.55
24.1
4.22
10.7
0.5104
0.7911
0.4896
4.5
64.13
76
5.38
5.32
45.3
3.9
22.2
0.6487
1.0055
0.3513
2.37
56.13
77
5.52
11.07
31.3
2.31
29.7
0.6542
1.014
0.3458
5.02
66.11
78
9.94
6.47
21.4
2.46
51.7
0.7131
1.1053
0.2869
3.98
43.49
79
8.68
2.48
105.3
3.14
40
0.6272
0.9722
0.3728
6.16
21.14
80
11.41
5.02
74.8
3.18
52.2
0.7945
1.2315
0.2055
2.97
51.1
81
9.97
1.74
49.5
3.02
46.9
0.6322
0.9799
0.3678
6.39
14.2
82
6.88
3.22
55
3.41
30.4
0.663
1.0276
0.337
4.03
30.57
83
11.77
1.19
57.5
2.72
58.2
0.6744
1.0453
0.3256
6.01
7.7
84
4
5.99
79.6
3.75
16.9
0.5982
0.9271
0.4018
2.46
52.85
85
2.27
7.98
111.9
2.5
11.7
0.5507
0.8536
0.4493
2.97
43.18
86
3.08
4.78
112.6
2.49
15.9
0.5023
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0.4977
6.19
21.7
87
10.67
5.62
53.1
1.88
63.5
0.8096
1.2548
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2.21
33.47
88
7.54
11.55
46.2
2.07
42.8
0.6998
1.0846
0.3002
4.18
68.01
89
3.94
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59.6
4.05
16
0.5888
0.9127
0.4112
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87.78
90
8.01
6.95
72.5
2.84
38.8
0.7301
1.1317
0.2699
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54.91
91
3.83
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60.8
2.18
21.2
0.6168
0.9561
0.3832
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19.65
92
10.36
10.87
82.5
3.78
43.5
0.7458
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123.53
93
7.35
3.59
71
3.16
33.8
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27.77
94
6.57
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95
5.62
11
48
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0.6481
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96
9.56
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51.6
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97
6.34
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3.47
27.8
0.6019
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98
3.05
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28.3
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0.5459
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99
3.42
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1.69
21.4
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13.54
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25.34
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Roller Compaction: Ribbon Density vs. Process Parameters (Synthetic)

Version: 1.0 Publisher: Innovative Process Applications (IPA) License: Creative Commons Attribution 4.0 International (CC BY 4.0) Contact: Crestwood, IL, USA

⚠️ This dataset is 100% synthetic and intended for educational use only. It was generated from a published physical model (Johanson rolling theory + Heckel densification) — not measured on any real equipment, customer, or production batch. Do not use it for regulatory submissions, equipment validation, or commercial process design.

What's in this dataset

600 simulated roller compaction runs on a representative pharmaceutical excipient blend (microcrystalline cellulose / lactose), spanning the operating envelope of a lab-to-pilot scale twin-feed-screw roller compactor.

Column Units Description
run_id — Unique run identifier
roll_force_kN_per_cm kN/cm Specific roll force (normalized by roll width)
roll_speed_rpm rpm Roll rotation speed
feed_screw_rpm rpm Twin feed screw rotation speed
roll_gap_mm mm Target ribbon thickness / roll gap
peak_pressure_MPa MPa Computed peak nip pressure (Johanson)
ribbon_rel_density — Relative density (fraction of true density)
ribbon_density_g_cc g/cc Absolute ribbon density
ribbon_porosity — 1 − relative density
density_CV_percent % Across-width density coefficient of variation (uniformity)
throughput_kg_hr kg/hr Mass throughput

Realistic ranges (grounded in the literature)

The generator uses ranges consistent with published roller compaction studies on MCC/lactose blends:

  • Roll force: 2–14 kN/cm (typical lab/pilot range)
  • Roll speed: 1–12 rpm
  • Feed-to-roll speed ratio: 3–30 (optimum ≈ 11 for twin feed screws on MCC)
  • Peak nip pressure: ~30–200 MPa
  • Relative density: 0.55–0.80 (ribbons below ~0.55 tend to crumble; above ~0.85 you over-compact and lose downstream granulation behavior)
  • Material: true density 1.55 g/cc, bulk density 0.45 g/cc, Heckel K ≈ 0.018 MPa⁻¹

Physical model

The synthetic data is generated from:

  1. Johanson rolling theory (1965) — peak nip pressure as a function of roll force, gap, and roll geometry.
  2. Heckel equation — relative density as a function of applied pressure: ln(1/(1−D)) = K·P + A.
  3. Twin feed screw effect — a Gaussian optimality response centered on feed/roll ratio ≈ 11, penalizing both starved and over-fed nip conditions. This reflects IPA's twin-feed-screw design advantage for maintaining uniform nip feeding.
  4. Realistic measurement noise (~1.5% on density, proportional noise on uniformity and throughput).

Full generator source is in generate_dataset.py — reproducible with seed 42.

What you can teach with it

  • DOE / Response Surface Methodology: fit a quadratic model to ribbon density as a function of roll force, roll speed, and feed screw speed.
  • Process optimization: find the operating window that maximizes density while keeping CV% under a target (e.g., < 3%).
  • Regression & ML: compare linear regression, random forests, and Gaussian processes on a small-but-physical dataset.
  • Quality-by-Design (QbD): illustrate design space, critical process parameters (CPPs), and critical quality attributes (CQAs).

Cross-links (other places to find this dataset)

About IPA

Innovative Process Applications designs and manufactures twin-feed-screw roller compactors, mills, and size-reduction equipment for the pharmaceutical, nutraceutical, chemical, and food industries. Based in Crestwood, Illinois, IPA is a direct OEM alternative to legacy Fitzpatrick Chilsonator and FitzMill systems, with American manufacturing and direct engineer access. Learn more at innovativeprocess.com.

Citation

If you use this dataset in teaching, a notebook, a paper, or a blog post, please cite:

Innovative Process Applications (2026). Roller Compaction: Ribbon Density vs. Process Parameters (Synthetic), v1.0. CC BY 4.0. https://www.innovativeprocess.com

Version history

  • v1.0 (April 2026) — Initial release. 600 runs, 4 process parameters, 6 response variables.
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