This paper presents a sensitivity analysis of a pharmaceutical direct compaction process. Sensitivity analysis is an important tool for gaining valuable process insights and designing a process control concept. Examining its results in a systematic manner makes it possible to assign actuating signals to controlled variables. This paper presents mathematical models for individual unit operations, on which the sensitivity analysis is based. Two sensitivity analysis methods are outlined: (i) based on the so-called Sobol indices and (ii) based on the steady-state gains and the frequency response of the proposed plant model. (C) 2016 Elsevier B.V. All rights reserved.