Eichler, ChristianChristianEichlerHeinrich, StefanStefanHeinrich2026-03-052026-03-052026-02-21Powder Technology 475: 122313 (2026)https://hdl.handle.net/11420/61881Roller compaction (RC) is widely used in pharmaceutical manufacturing but produces ribbons with non-uniform porosity, complicating the prediction of tablet properties. Here, we present a reduced-order framework that links roller compaction and tableting by minimally extending established constitutive models to predict tablet porosity and tensile strength with low additional data demand. Peak RC stress was calculated using the Johanson model as a function of specific compaction force, while ribbon porosity was estimated with the Kawakita relation, which we extended to capture pre-compaction effects, enabling estimation of the final tablet porosity. Tablet tensile strength was described by the Ryshkewitch–Duckworth relation, extended by a pressure-like term representing granule hardening during pre-compaction. A global sensitivity analysis was performed, and the framework was validated against literature data for microcrystalline cellulose (MCC) and mannitol, including response-surface evaluation over RC and tableting conditions. Fitting the empirical parameters yielded excellent agreement for tablet porosity (MCC: R² = 0.99; mannitol: R² = 0.96) and tensile strength when using experimental porosity (MCC: R² = 0.98; mannitol: R² = 0.99). Predicting tensile strength via model-predicted porosity remained strong. Sensitivity analysis identified tableting pressure and Kawakita model parameters as the dominant factors influencing final porosity and tensile strength. The two simple model extensions integrate RC and tableting into a unified, easy-to-apply framework suitable for parameter exploration and model-based design of experiments. Despite known simplifications, the framework consistently captured trends for both plastic and brittle excipients.en0032-59102026Elsevierhttps://creativecommons.org/licenses/by/4.0/Global sensitivity analysisJohansonKawakitaRoller compactionRyshkewitch-DuckworthTablet pressTabletingTechnology::610: Medicine, HealthNatural Sciences and Mathematics::530: Physics::530.4: States of Matter::530.41: Mechanics of SolidsJournal Articlehttps://doi.org/10.15480/882.1681810.1016/j.powtec.2026.12231310.15480/882.16818Journal Article