Tips for Tablets

Film coating is a widely used process in pharmaceutical manufacturing, enhancing tablet appearance, taste, and stability. However, over-coating during film coating can lead to inconsistent tablet quality, excessive tablet weight, and impaired dissolution rates. Over-coating occurs when the film is applied in excessive amounts, leading to a thick, uneven coating. The result can be delayed drug release, poor bioavailability, and reduced tablet performance.
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Sugar-coating is a critical process in tablet manufacturing, used to enhance the appearance, taste, and stability of tablets. However, achieving uniformity and consistency in the coating process can be challenging, especially when optimizing the spray rates during the sugar-coating process. Excessive spray rates can lead to uneven coating, longer drying times, and excess product loss, while too low spray rates may result in incomplete or inconsistent coatings.
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Wet granulation is a crucial step in pharmaceutical tablet manufacturing, but it comes with its own set of challenges. One of the most common issues in wet granulation is binder overuse, which can negatively impact the granule properties and tablet performance. When binders are used in excess, it can lead to poor flowability, poor compression properties, and even stability issues with the final product.
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Overheating during tablet compression is one of the most significant challenges in the pharmaceutical manufacturing process. Excessive heat can result in a range of issues, from API degradation and tablet capping to inconsistent dissolution rates and mechanical failure of the tablets. Overheating occurs when friction, inadequate cooling, high compression speeds, and improper lubrication create elevated temperatures in the compression chamber. Controlling heat is essential not only to preserve the stability and efficacy of the active pharmaceutical ingredients (APIs) but also to maintain tablet uniformity and compliance with regulatory standards.
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Tablet thickness and hardness are critical quality attributes in pharmaceutical manufacturing that directly affect tablet integrity, dissolution, and patient compliance. Variations in these parameters can lead to dose inconsistencies, mechanical failure, and regulatory non-compliance.
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Tablet weight variation is a common issue in pharmaceutical manufacturing that can lead to dose inconsistency, regulatory non-compliance, and batch rejection. Several factors, including poor powder flow, incorrect die fill, and improper machine calibration, contribute to weight inconsistencies.
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Roller compaction is a critical dry granulation technique used in tablet manufacturing to improve powder flowability, compressibility, and uniformity. However, challenges such as poor ribbon density, inconsistent granule size, and improper process parameters can affect tablet quality.
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Tablet lamination is a serious defect in pharmaceutical manufacturing where a tablet splits into multiple layers during or after compression. This issue affects tablet integrity, stability, and patient compliance. Poor powder properties, excessive compression force, and improper excipient selection are common causes of lamination.
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Tablet sticking and picking are common issues in pharmaceutical manufacturing that occur when powders adhere to the punch surfaces or tooling, leading to defective tablets. Poor lubrication, improper compression settings, and formulation imbalances are primary causes.
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Cross-contamination in tablet manufacturing is a significant concern that can lead to product recalls, regulatory non-compliance, and potential health risks. Contamination can occur due to poor facility design, inadequate cleaning procedures, ineffective personnel handling, or airborne particle transfer.
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Effervescent tablets are a unique dosage form that rapidly dissolves in water, releasing carbon dioxide to create a solution for easy administration. These formulations enhance patient compliance, drug solubility, and bioavailability. However, ensuring stability, rapid dissolution, and controlled effervescence presents several formulation challenges.
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Dispersible tablets are designed to rapidly break down in water, forming a suspension for easy administration. These formulations are particularly beneficial for pediatric, geriatric, and dysphagic patients. However, challenges such as slow disintegration, sedimentation, and poor mouthfeel can impact effectiveness and patient compliance.
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