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Direct compression is the simplest and most cost-effective process where APIs and functional excipients such as filler binders or lubricants are mixed in a screw mixer with pre-mixed powders then directly compressed with a tablet press.
Advantages of direct compression costs are low production is fast and efficient and works with water and heat-sensitive APIs. However, this can be difficult for low doses due to poor content uniformity, plus pre-mixed powders require good flowability to ensure perfect cavity filling. Good flow behavior can speed up the process by preventing arching, bridging or ratholes during compression.
Flow characteristics are measured by angle of repose. A small angle indicates good flowability if the pre-mixed powder has insufficient flow properties as indicated by a high angle of repose. Granulation can be done by a wet or dry manufacturing process to produce larger and rougher particles or granules that increase flow properties by reducing particle surface area and reducing dust grain size.
