Twin Roller Compactor plays an important role in the pharmaceutical industry. Optimization of Twin Roller Compactor has improved product quality, process efficiencies, personnel ergonomics, reduced airborne contamination and machine noise. Twin Roller Compactor feeding and design system improvements have also significantly advanced equipment performance.

In several experiments, Miller studied and described the effects of horizontal twin auger feed-screws, under partial vacuum, which were enclosed in a novel stainless steel sealed system prior to the rolls. Essentially, feed stock was vacuum deaerated just prior to roller compaction. The experimental design showed the compactor's deaeration and feed system designs significantly increased compaction output and minimized powder leakage when compacting very low density blends, less than 0.3 g/cm3 . Miller concluded from his studies that there are four key processing conditions to consider when optimizing roller compaction throughput:

1. Adequate powder supply must enter the roll-pair-gripping zone.
2. Powder must be fully conveyed into the narrowest part of the roll gap.
3. Roll pressure must be distributed as uniformly as possible over the entire roller-gripped mass.
4. Vacuum deaeration must be adequately and effectively distributed before the nip roll region.