Tips for Tablets

High-speed granulation is a widely used process in the pharmaceutical industry to improve the flowability, compressibility, and uniformity of powders used in tablet formulations. While this technique is essential for ensuring optimal tablet characteristics, it can also lead to the loss of active pharmaceutical ingredients (APIs) during granulation if not properly controlled. API loss can negatively affect tablet dosage uniformity, therapeutic efficacy, and overall product quality.
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Coating pans are essential equipment in the pharmaceutical industry used for applying coatings to tablets. After the sugar-coating process, cleaning the coating pan thoroughly becomes a critical task to ensure that cross-contamination does not occur in subsequent batches and that the pan remains in good operational condition. Sugar-coating residue is particularly challenging to remove, as the sticky nature of the sugar coating can cause buildup, making cleaning more difficult. Incomplete cleaning may affect the quality of future batches and lead to contamination of ingredients, especially if different formulations or active pharmaceutical ingredients (APIs) are involved.
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Bilayer tablets are a popular formulation in the pharmaceutical industry, offering controlled release of two different active pharmaceutical ingredients (APIs) or distinct release profiles for a single API. However, one common issue faced during the production of bilayer tablets is layer separation during compression. This occurs when the two layers of the tablet fail to bond properly during the compression process, leading to defects such as splitting, delamination, or uneven release rates. Layer separation can compromise the stability, efficacy, and quality of the final tablet.
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Sugar-coated tablets are commonly used in the pharmaceutical industry due to their ability to mask unpleasant tastes, enhance tablet appearance, and provide a protective barrier for the active pharmaceutical ingredient (API). However, one of the common issues faced during the sugar-coating process is coating layer flaking. Flaking occurs when the sugar coating detaches from the tablet surface, leading to incomplete coverage, defects, and potential exposure of the API. This can compromise both the aesthetic quality and the functionality of the tablets, affecting their stability, bioavailability, and market acceptance.
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In pharmaceutical tablet manufacturing, uniformity of powder mixture is crucial for achieving consistent dosage and tablet quality. Vibratory feeders are often used to transport powders into the tablet press, but one of the common challenges in this process is powder segregation. Powder segregation occurs when the components of a powder blend separate based on factors like particle size, density, or shape. This can lead to inconsistent filling, incorrect API dosage, and variability in tablet weight and strength, which can result in poor product quality and regulatory non-compliance.
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Enteric-coated tablets are designed to protect the active pharmaceutical ingredient (API) from stomach acid and to deliver it in the intestine where the drug is absorbed. However, one of the challenges associated with the manufacturing of enteric-coated tablets is the control of residual moisture in the coating. Excess moisture can lead to poor film integrity, cracking, or dissolution issues, affecting the overall stability, bioavailability, and shelf life of the product. Moisture can also degrade the API or interfere with the coating’s protective function, leading to inconsistent drug release profiles.
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Tablet manufacturing involves the use of various excipients and active pharmaceutical ingredients (APIs) in powder form. These powders are fed into the tablet press hoppers, where they are compressed into tablets. A common issue faced during this process is powder bridging, a phenomenon where the powder forms a bridge or arch over the hopper outlet, obstructing the flow of powder into the die cavity. This can lead to uneven tablet weight distribution, variable tablet hardness, and other defects that affect the quality of the final product.
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Hygroscopic tablets, which absorb moisture from the air, present unique challenges during the drying process in tablet manufacturing. The weight loss that occurs in hygroscopic tablets during drying can affect both the quality of the product and its stability. Moisture loss can lead to changes in the tablet’s physical properties, such as hardness, friability, and dissolution rate, and can also lead to API degradation if the drying process is not properly controlled.
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Sustained release tablets are designed to deliver a drug at a controlled rate over an extended period. The coating used in these tablets is critical for ensuring the release of the drug according to the desired time frame. However, one of the major challenges in the production of sustained release tablets is ensuring effective adhesion of the coating to the tablet surface. Poor adhesion can result in coating defects, such as cracking, delamination, or incomplete drug release, all of which affect the therapeutic effectiveness of the tablet.
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The post-coating process is a crucial step in tablet production where tablets are dried after the application of coatings. During this process, the tablets need to be dried thoroughly to remove excess solvent and moisture from the coating, ensuring the final product meets the required physical and chemical properties. However, overdrying can be a significant issue that leads to a host of problems, including degradation of the coating, altered tablet properties, and reduced drug efficacy. Overdrying can also affect the appearance of tablets and cause cracking, brittleness, or surface defects.
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Coating machines are crucial for the pharmaceutical manufacturing process, as they apply protective or functional coatings to tablets. A common issue that can arise during the coating process is spray nozzle clogging. This problem can result in uneven coating application, poor tablet appearance, and a compromised drug release profile. Clogged nozzles can lead to production delays, wasted materials, and increased costs due to the need for manual cleaning and reprocessing.
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Active Pharmaceutical Ingredients (APIs) are sensitive to various environmental factors, and one of the most critical factors is heat. Heat degradation can significantly affect the stability, potency, and efficacy of APIs. In pharmaceutical manufacturing, especially during the compression process, heat can be inadvertently generated, potentially leading to API degradation. During compression, tablets are subjected to high pressure and sometimes elevated temperatures, which can cause thermal decomposition or other forms of degradation of heat-sensitive compounds.
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