Basics of tableting and coating techniques

a brief overview of processes and machines

Which machine do I need for which process?

The right choice of process and machine is crucial for your tablet compression and coating, as it has a direct influence on production quality, efficiency and cost-effectiveness.

The challenge in the

tableting process: Which tableting process do I use? Can my active ingredient be pressed directly or do I need to pre-treat it? Do I need a single-layer or multi-layer tablet?

Coating process: Does my tablet need a coating to give it more stability, to mask odors or tastes, to maintain a certain release profile or to add more color?

1. Tableting process

Sometimes it is necessary to pre-treat the still powdery tablet mass. For example, if the powder is difficult to compress or has poor flow properties. The following methods can be used to improve this:

Dry Compression

Used for active ingredients that are very sensitive to moisture (hygroscopicity) or heat (thermolability). They can disintegrate or lose their effectiveness during wet granulation. Dry compression avoids the use of liquids and thus protects the active ingredients from moisture; highly hygroscopic substances (water-attracting) can clump together during wet granulation and make tablet production more difficult. Dry compression reduces this risk.

Wet Compression

This common process is used to improve the flowability of fine particulate powders. Or for low compressibility. Wet granulation can improve compressibility by changing the particle structure and increasing the surface area. The resulting granules have better cohesion and are easier to compress into tablets.

Direct Compression

In this process, the powder of the active ingredient and excipients is pressed directly in a tablet press without prior granulation or compression.

The production process is quick, cost-effective and simple.

Multilayer Pressing

In this process, tablets are pressed in several layers. Each layer can contain different active ingredients, release profiles or colors.

Single Punch Press

A single punch press, also known as an eccentric press, is a simple and compact machine for producing tablets in small batches or for research and development purposes. Its mode of operation is based on a single pair of punches and a die.

Rotary Press

The powder is produced in a machine with several rotating stations. Machines for large-scale production can be equipped with over 100 punches and can press well over 1 million tablets per hour. Ideal for mass production due to high production speed.

Tableting machine overview

BIOGRUND works with tableting machines from the following manufacturers:

2. coating process

Filmcoating

Film coating is a process in which tablets are coated with a thin, even layer of one or more polymers. This layer, also known as a film, can fulfill different functions and improve the properties of the tablet. Compared to coating, the process times for film coating are significantly faster.

Sugar Coating

Traditional coating method in which numerous layers of a sugar solution are applied. The end product, a coated tablet, has a smooth, shiny and well-insulating surface. Aesthetically pleasing (colorful, shiny dragee), protects the active ingredient from light & moisture while maintaining a neutral odor and sweet taste. The disadvantage is extremely long processing times.

Hot Melt Coating

Here, one or more active ingredients are dispersed in a molten matrix of polymers or other materials (waxes) and then applied as a thin layer to tablets or other solid dosage forms (particles, pellets). The matrix solidifies on cooling and forms a coating that can fulfill various functions. It can be applied solvent-free and offers good barrier properties against moisture.

Drum coater

Application: Film coating of pharmaceutical and dietary supplement tablets. A distinction is made here between perforated and smooth-walled drums. A drum with perforations enables efficient air flow and faster drying times, which has a positive effect on process time.

Fluidized bed coater

Application: For coating pellets, granules, particles, and mini tablets. Fluidized bed technology enables uniform coating. Also suitable for encapsulating flavors and fragrances or for granulation. Also used in the manufacture of instant products (e.g., coffee powder).

Sugar coating pan

Application: For applying sugar coatings, chocolate coatings in the confectionery industry, and protective and gloss coatings for pharmaceutical products (dragees). Layer-by-layer method: application/distribution/drying. Drying is carried out using warm air or an open system. Coating pans are also used on a laboratory scale (R&D) as film coaters.

Coating machine overview

BIOGRUND works with film coating machines from the following manufacturers:

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