Top 4 Reasons for Tablet Defects
In recent years we have seen important improvements in tablet production machinery and quality control systems. However, the modern tablet production process still has challenges to overcome to provide flawless end products. To ensure high product quality, the design of the sorting and filling machine plays a crucial role.
According to the latest reports, the global sorting machine market was valued at $ 3.81 billion in 2020. The industry is expected to grow at 5.9% (CAGR) from 2021 to 2028. The growth is mostly due to pharmaceutical demand, where such equipment is used to select tablets based on their weight, size, and shape to maintain quality standards during production.
In this article, we will discuss the main defects that can occur in pharmaceutical production and packaging. At the same time, we will introduce you to Pharmapack 360° Filling and Sorting Machine.
Tablet defects
Tablet defects are deficiencies that are usually encountered in tablet formulation. For example, depending on technician experience, production process, and machinery design, tablets can develop certain defects which may be immediately apparent or appear after storage.
Listed below are the main defects associated with tablet manufacturing and packaging.
Capping
Capping occurs when a fracture appears at the top of the tablet, and the cap separates itself from the body of the solid tablet. Capping is often induced by air trapped in the powder material during the compression stage or subsequent operations, such as coating, packing, and shipment. Another cause can be related to the press failing to compress the formulation due to the collection of powder fines. Capping is often easy to resolve either by increasing the dwell time or by careful analysis of the formulation and production process.
Lamination
Lamination is the term used for a split in the tablet anywhere but at the top. Similar to capping, lamination usually happens due to the over-compression of the tablet. Too much compression can lead to the granules flattening out, thus preventing them from locking together. To prevent lamination, the thickness of the tablet needs to be adjusted, and the dwell time increased to allow the fine particles to merge. Another solution is to use a tapered die instead of a cylindrical one, as it does not exhibit laminating problems.
Sticking
The sticking defect happens when the granules of a formulation become stuck to the face of the press punch. Such a problem can happen anytime during production, but most likely during the initial setup of the press. Among the different causes of sticking, we can have a limited extent of lubrication, rough tooling surface, or slight dampness of the tablet granulation. To avoid sticking during pressing, the hardness of the tablet can be increased by making it thinner. Another option is to increase the dwell time to ensure that the wet granules stick to the other granules instead of the punch face.
Picking
On the other hand, picking occurs when the granules get stuck to the punch surface and erode from the tablet surface. Such a term describes products sticking within the letters, logos, or designs on the punch faces. Picking may be caused by the compression of granules that are not properly dried. Another instance can be when the powder blending is incomplete, such as the lubricant not blending with the granules. To prevent picking defects, we can enhance hardness by making the tablet thinner and increasing dwell time to make the wet granules adhere to other granules rather than adhering to the punch faces.
Pharmapack Equipment Recommendation
Phamapack has developed the “360° Filling and Sorting Machine” to ensure product integrity and the highest quality for pharmaceutical manufacture.
Pharmapack solution is an automatic counting, filling, and sorting equipment for pills, tablets, soft and hard capsules, and other solid granules. Widely used in the pharmaceutical industry, the machinery adopts a “European design” with its AISI 304 stainless steel frame, AISI 316L stainless steel contact parts, and spacious cleaning platform on the top.
In compliance with GMP and FDA, the machinery uses innovative camera detection, rejection system, and static weighing detection system in both the front and back end to realize online rejection of defective tablets.
In terms of quality control, the machine is equipped with double wide-angle miniature cameras, which enables manufacturers to achieve 360° detection and infrared counting (up to 100 frames/second).
Overall, Pharmapack 360° Filling and Sorting Machine support manufacturers by improving product quality and assuring end-user satisfaction.
To receive a quotation, do not hesitate to contact us.