The tablet compression procedure is a widely employed technique in solid dosage production in the pharmaceutical industry. One thing worth noticing is that it comprises many challenges. Various tablet compress problems may appear during the manufacturing process, leading to compromise in product quality, reduced efficacy, and increased production cost.
The professionals in the pharma enterprises should understand and learn how to address tablet compression issues. In this article, we have included some crucial problems in tablet compression and provided effective solutions to overcome them. So, no further delay. Let’s get started!
What is Tablet Compression?
Many people know about this process, but we will give you a quick reminder about it. So, check out the short description of the tablet compression procedure:
“A tablet compression is a process that helps in the pharmaceutical tablet formation by subjecting the dry granular powders. It does it under an adequate pressure to make the particles cohere.”
Moreover, the fundamental principle used in tablet compression machines is hydraulic pressure. It gets transmitted unreduced with the help of static fluid. When an external pressure is applied, the static fluid moves in all directions in the same proportion. Besides, it is also possible to multiply the force as required.
7 Common Tablet Compression Problems and Remedies
Let’s check out some of the tablet problems during compression that can affect the quality of the product. The best thing is that solutions are also mentioned.
1. Cracking
Cracking is a tablet compression issue in which small cracks can be identified on the tablet’s surfaces. The cracks are significant to see on the top and bottom sides of the tablet. Some main reasons behind this problem involve too large or too dry granulation, tablet expansion, extremely cold granulation, and more.
Solutions:
The following are some remedies that you can try to avoid cracking:
- Improvement of granulation by adding dry binders
- Decreasing the granulate size with more fine particles
- Adjustment of the ambient temperature
2. Sticking To Punches
Another well-known tablet problem during compression is sticking to punches. It can be defined as it appears when the particles or granules of the formulation get stuck or attached to the punch cup face. It results in defective tablet production. Various possible reasons behind this issue can be incomplete granulate drying, low level of lubrication content, soft or weak granulates, etc.
Solutions:
If you want to deal with this tablet compression problem, you can:
- Use of the desired lubricant
- Completely drying the granulate
- Adjust compression force in the production
- Polish punch’s surface
3. Weight Variations
The next common issue with tablet compression is the weight variation. It means that every manufactured tablet doesn’t have the same weight. There could be many reasons behind this problem. A list of few includes incomplete die filling, high granulate density variation, insufficient flowability, high-pressure speed, and others.
Solutions:
Several remedies are there to reduce the chances of this compression tablet problem. Check some below:
- Ensure to avoid free fall of granulate to prevent decomposition
- Utilize flow enhancers for optimal flowability of granulate
- Increase the filling time and lessen the press speed
4. Tablet Hardness
Tablet hardness is one more problem in tablet compression. It is usually determined as an extremely hard tablet that has excessive bonding potential between excipients and active ingredients. It can result in preventing the expected dissolution of the tablets for accurate dosage. The hardness of the tablet can occur due to the tablet weight variation, bulk density variation, inhomogeneity of granulate particles, old ejection blade, and more.
Solutions:
Here are some correctives that you can use to avoid this tablet problem during compression:
- Use an efficient amount of binding agent
- Add suitable ingredients for better compacting properties
- Attain the homogeneous bulk density
5. Capping and Lamination
Capping and lamination are also common issues with tablet compression. It often occurs during scale-up. If we elaborate, capping is the partial or total removal of the tablet crown, whereas lamination is tablet separation in two or more layers. Some reasons that can lead to capping and lamination involve granulate separation, too many fine granulate particles, less suitable binder, more hydrophobic lubricant, etc.
Solutions:
Check some of the best solutions for this compression tablet problem:
- Decrease the API amount
- Add enough binding and absorbent agents
- Reduction in the tablet press
- Drying or moisturizing the granulates
6. Binding
Another tablet compression issue that frequently occurs in production is binding. It can be described as the problem that occurs when the tablet takes the die’s hold and splits during the press. When the process is running, a film is built on the die or moulding part, restraining the tablet ejection. A few reasons behind such compression problems in tablets are over moisture in granulate, extremely hard granulate for lubricant, unsuitable punch, and more.
Solutions:
The most common remedies to avoid this problem involves:
- Increasing the area for effective ejection
- Adding more drying time for granulation
- Lowering the temperature, it is too warm
7. Chipping
The following problem that is very common to notice is chipping in the tablet compression. Chipping can be determined as the edges breaking of the tablet during production. Various reasons can lead to this chipping problem in tablet compression. Some significant ones are extreme granulate drying, extra binding, deep concavity to compress, sticking on punch faces, and others.
Solutions:
If you want to deal with this compression tablet problem, you can use the following remedies:
- Increase the lubricant or dry granulate appropriately
- Utilize suitable binding agents
- Addition of hygroscopic substances
- Minimizing the concavity of punch faces
High Quality Tablet Compression Machine from HUADA Pharma
After going through various tablet compression problems and remedies, we are providing you with effective machines to perform tablet compression!
HUADA Pharma is a globally leading brand that manufactures and sells the best pharmaceutical equipment. We include this best tablet compressing machine by HUADA Pharma below:
TabCN-29B Automatic Rotary Tablet Compression Machine
This TabCN-29B rotary tablet press from HUADA Pharma has automatic rotations with perfect frequency control and uninterrupted tablet pressing. It is effective for minimal tablet problems during compression. Majorly, this machine gets utilized for the manufacturing of tablets in the pharma industry. It can be utilized in different industries like food and chemical. Besides, it can press round, special-shaped, and double-sided tablets with lettering.
Features:
- This machine is run by the motor through a synchronous toothed belt together with worm and worm gear.
- The outer cover of the equipment is completely enclosed and composed of austenite stainless steel.
- With effective frequency control of motor speed, you will get sturdy, safe and accurate rotation during production.
Final Word
At the end of the day, there are possibilities for various problems in tablet compression. So, the remedies are essential to overcome the issues effectively. We have already discussed the most common issues and their solutions.
Every pharmaceutical manufacturer must monitor and control various factors to eliminate tablet compression challenges. The practical solution for such problems is to use top-notch tablet compression machines. HUADA Pharma provides high-quality equipment to pharmaceutical companies. Visit the website and see various machine options to improve production in your pharma firm.