Tips for: Solid Oral Dosage Forms

Poor powder flow is a common challenge in tablet manufacturing. It can lead to inconsistent die filling, weight variation, and even machine downtime. This issue typically arises due to factors such as irregular particle size, high moisture content, static buildup, or insufficient lubrication.
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Segregation refers to the separation of different components in a powder blend, leading to inconsistencies in tablet composition. This occurs when powders of varying particle sizes, densities, or shapes are mixed but fail to remain homogeneously distributed. Segregation can result in uneven API (Active Pharmaceutical Ingredient) distribution, causing substandard tablets that may fail quality control tests.
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Double-impression occurs when a tablet receives an unintended duplicate marking during the compression process. This defect is primarily associated with improperly functioning punches, where one or both punches move freely in the die and imprint a second time. Double-impression affects the tablet’s aesthetics and can result in regulatory non-compliance.
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Air entrapment occurs when air pockets are trapped inside the core of a tablet during the compression process. This issue can lead to defects such as capping, lamination, or weakened mechanical strength. Entrapped air prevents proper bonding between powder particles, reducing the overall quality of the tablet and its ability to meet pharmacopoeial standards.
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Tablet breakage is a common issue in high-speed tablet compression, where tablets crack, chip, or break during production or handling. The high speeds involved in modern tablet presses exert significant stress on both the formulation and the machine components, increasing the risk of defects.
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Tablet hardness plays a crucial role in immediate-release formulations. It directly affects the mechanical strength of the tablet, its disintegration time, and the release of active pharmaceutical ingredients (APIs). Hardness that is too low may result in tablets breaking during handling or packaging, while excessive hardness can slow disintegration and delay drug release, defeating the purpose of immediate release.
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Powder sticking to punches, commonly known as “sticking,” is a frequent issue in tablet manufacturing. It occurs when powder adheres to the punch faces instead of compacting properly within the die cavity. This problem can lead to defective tablets, production delays, and increased machine wear.
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Powder flowability is a critical factor in tablet manufacturing. It determines how well powder particles flow into the die cavity during the compression process, directly impacting tablet uniformity, weight, and quality. Poor flowability can lead to weight variation, capping, lamination, and other production defects.
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Tablet lamination is a defect in pharmaceutical tablet production where the tablet separates into layers after compression. This can occur during production, packaging, or even storage. Lamination compromises the tablet’s integrity, appearance, and functionality, making it a serious issue for pharmaceutical manufacturers.
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Tablet compression force plays a critical role in ensuring the uniformity, strength, and efficacy of tablets. During manufacturing, the applied force determines how tightly the powder particles bond, directly impacting the tablet’s hardness, friability, and disintegration time. Incorrect compression force can result in defects such as weight variation, capping, or lamination.
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Tablet capping refers to a manufacturing defect where the top or bottom layer of a tablet separates or breaks off during or after compression. This issue compromises the integrity, efficacy, and appearance of the tablet, leading to potential product rejection and financial loss.
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Weight variation in tablet manufacturing occurs when tablets from the same batch exhibit inconsistent weights. This problem not only affects product quality but also impacts the therapeutic efficacy of the medication. It can lead to regulatory non-compliance and financial losses due to rejections or recalls.
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