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Tips for: Solid Oral Dosage Forms

Formulation Development Challenges for Pediatric Capsule Dosage Forms

Posted on May 16, 2025 By Admin

Pediatric patients present unique challenges in pharmaceutical formulation, particularly when it comes to capsule dosage forms. Children often have different pharmacokinetic profiles, swallowing abilities, and taste preferences compared to adults, making it difficult to design effective and acceptable dosage forms. Hard gelatin capsules and soft gelatin capsules, which are commonly used for adult formulations, may not be suitable for pediatric use due to size, taste, and ease of administration concerns. Moreover, the need for accurate dosing, safety, and palatability complicates the development process for pediatric capsules.
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Capsules (Hard & Soft Gelatin)

Complexity in Designing Formulations for Site-Specific Drug Release

Posted on May 15, 2025 By Admin

Site-specific drug release is a challenging but critical aspect of pharmaceutical formulation, especially for drugs that require targeted delivery to specific regions of the gastrointestinal tract or other targeted areas of the body. The complexity of designing such formulations arises from the need to overcome physiological barriers such as varying pH levels, enzymatic activity, and gastric emptying times. Achieving site-specific release often requires the use of sophisticated drug delivery systems that can release the API in a controlled and predictable manner at the intended site. This involves intricate formulation strategies that must balance drug solubility, stability, and bioavailability, while also ensuring safety and efficacy.
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Capsules (Hard & Soft Gelatin)

Avoiding Uneven Color Distribution in Sugar-Coated Tablets

Posted on May 15, 2025 By Admin

In the pharmaceutical industry, sugar coating is commonly used to improve the appearance, taste, and stability of tablets. A uniform and attractive sugar coating is essential for the aesthetic appeal of the product, as well as for ensuring patient compliance, particularly when the tablets are intended for pediatric or geriatric patients. One common issue encountered during the sugar coating process is uneven color distribution, which can result in visually unappealing tablets and indicate potential coating defects that could compromise the quality and consistency of the product.
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Tablets

Problems with Capsule Weight Gain During Stability Studies

Posted on May 15, 2025 By Admin

Capsule weight gain during stability studies is a significant challenge in the pharmaceutical industry, particularly for soft gelatin capsules and liquid-filled capsules. This issue arises when the capsule shell absorbs moisture or other environmental elements during storage, leading to an increase in weight. The weight gain can be caused by factors such as humidity, temperature fluctuations, and the permeability of the capsule material. This problem can compromise the stability, safety, and efficacy of the product, as the weight gain can alter the dissolution rate, drug release profile, and the capsule’s overall integrity, potentially impacting regulatory compliance and market acceptance.
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Capsules (Hard & Soft Gelatin)

Managing Over-Spray in Film Coating Machines

Posted on May 15, 2025 By Admin

Film coating is a critical process in pharmaceutical tablet production, where a thin layer of coating is applied to the tablet surface to enhance its stability, appearance, and release properties. Over-spray, a common issue in film coating machines, occurs when excess coating material is sprayed onto the tablet bed, leading to wasted coating material, poor coating quality, and even tablet defects such as streaking or uneven coating thickness. Over-spray can increase production costs, reduce coating efficiency, and compromise the final product’s appearance and performance.
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Tablets

Limited Compatibility of Acid-Sensitive APIs with Hard Gelatin Capsules

Posted on May 15, 2025 By Admin

Hard gelatin capsules are commonly used for drug delivery, but when the active pharmaceutical ingredient (API) is acid-sensitive, compatibility with the gelatin shell becomes a challenge. Acid-sensitive APIs may degrade or lose efficacy when exposed to acidic conditions, such as those found in the stomach. This is particularly problematic in hard gelatin capsules, as the gelatin shell dissolves in the stomach’s acidic environment, potentially exposing the API to degradation before it reaches its intended site of action. For such drugs, formulations that protect the API from stomach acid are essential to ensure therapeutic efficacy and patient safety.
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Capsules (Hard & Soft Gelatin)

Inconsistencies in Fill Weight Due to Hygroscopic Ingredients

Posted on May 14, 2025 By Admin

Hygroscopic ingredients, such as certain excipients or active pharmaceutical ingredients (APIs), are prone to absorbing moisture from the surrounding environment. This moisture absorption can cause the weight and volume of these ingredients to change, leading to inconsistencies in the fill weight of capsules. These variations can result in inaccurate dosing, affecting the efficacy, safety, and quality of the final product. In the case of hard gelatin or soft gelatin capsules, achieving consistent fill weight is crucial for meeting regulatory requirements and ensuring therapeutic effectiveness. Addressing the challenges posed by hygroscopic ingredients is key to ensuring uniformity in capsule formulations.
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Capsules (Hard & Soft Gelatin)

Controlling Humidity in Coating Rooms for Immediate Release Tablets

Posted on May 14, 2025 By Admin

Humidity control in coating rooms is essential for ensuring the successful application of coatings, particularly for immediate release (IR) tablets. During the tablet coating process, humidity can significantly impact the quality and consistency of the coating. In the case of IR tablets, an effective coating is necessary to provide stability, protect the API, and ensure the desired dissolution profile. Excess moisture or lack of humidity control can result in issues such as poor adhesion, uneven coating, or tablet defects such as peeling or cracking.
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Tablets

Difficulty in Achieving Rapid Onset of Action in Hard Gelatin Capsules

Posted on May 14, 2025 By Admin

Hard gelatin capsules are widely used for oral drug delivery, but achieving a rapid onset of action in these capsules can be challenging. For certain drugs, the speed at which the API is released and absorbed into the bloodstream is crucial for therapeutic efficacy, especially for acute conditions where immediate relief is needed. However, the physical properties of hard gelatin capsules, such as their dissolution rate and the rate at which the API is released, can affect the onset of action. Inadequate formulation or capsule design can lead to slow dissolution or incomplete absorption, delaying the drug’s effects and reducing its clinical effectiveness.
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Capsules (Hard & Soft Gelatin)

Addressing Lamination in Oval and Odd-Shaped Tablets

Posted on May 14, 2025 By Admin

Lamination, or the separation of layers in tablet compression, is a common issue that can occur during the production of tablets, especially for complex shapes such as oval and irregularly shaped tablets. Lamination occurs when the tablet layers do not bond properly, leading to separation along the plane of compression. This issue is particularly troublesome for manufacturers of controlled-release formulations, where uniformity and tablet integrity are essential for therapeutic effectiveness.
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Tablets

High Risk of Microbial Contamination in Aqueous-Based Soft Gelatin Formulations

Posted on May 14, 2025 By Admin

Aqueous-based formulations, such as those used in soft gelatin capsules containing suspensions, emulsions, or liquid-filled capsules, face significant challenges with microbial contamination. Due to the high moisture content in these formulations, they provide an ideal environment for microbial growth if not properly controlled. Microbial contamination can lead to product spoilage, reduced shelf life, and potential health risks to patients. In addition, regulatory agencies such as the FDA and EMA require strict controls over microbial contamination in pharmaceutical products, making it essential for manufacturers to implement effective strategies to prevent contamination during formulation, filling, and storage.
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Capsules (Hard & Soft Gelatin)

Troubleshooting Core Cracking in Bilayer Tablet Compression

Posted on May 14, 2025 By Admin

Bilayer tablets are an important dosage form in pharmaceutical manufacturing, as they allow for the controlled release of two different active pharmaceutical ingredients (APIs) in a single tablet. This dual-layer structure is particularly useful for combination therapies and for achieving specific drug release profiles. However, one common problem encountered during the production of bilayer tablets is core cracking, where the inner layer of the tablet cracks or splits during the compression process. Core cracking can lead to product defects, reduced drug stability, and compromised therapeutic efficacy.
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Tablets

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