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Tablet:Operations involved in tablet manufacturing

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Tablet Manufacturing methods
Previous Page: Ideal properties of API for formulating tablets

Contents

Introduction

The manufacture of oral solid dosage forms such as tablets is a complex multi-stage process under which the starting materials change their physical characteristics a number of times before the final dosage form is produced. Traditionally, tablets have been made by granulation, a process that imparts two primary requisites to formulate: compactibility and fluidity. Both wet granulation and dry granulation (slugging and roll compaction) are used. Regardless of weather tablets are made by direct compression or granulation, the first step, milling and mixing, is the same; subsequent step differ. Numerous unit processes are involved in making tablets, including particle size reduction and sizing, blending, granulation, drying, compaction, and (frequently) coating. Various factors associated with these processes can seriously affect content uniformity, bioavailability, or stability.

FIGURE.20. VARIOUS UNIT OPERATION SEQUENCES IN TABLET MANUFACTURING
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FIGURE.20. VARIOUS UNIT OPERATION SEQUENCES IN TABLET MANUFACTURING
FIGURE.21.TYPICAL MANUFACTURING PROCESS OF TABLET
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FIGURE.21.TYPICAL MANUFACTURING PROCESS OF TABLET




TABLE.22. TYPICAL UNIT OPERATION INVOLVED IN WET GRANULATION, DRY GRANULATION AND DIRECT COMPRESSION(13)

WET GRANULATION

DRY GRANULATION

DIRECT COMPRESSION

1. Milling and mixing of drugs and excipients

1. Milling and mixing of drugs and excipients

1. Milling and mixing of drugs and excipients

2. Preparation of binder solution

2. Compression into slugs or roll compaction

2. Compression of tablet

3. Wet massing by addition of binder solution or granulating solvent

3. Milling and screening of slugs and compacted powder

 

4. Screening of wet mass

4. Mixing with lubricant and disintegrant

 

5. Drying of the wet granules

5. Compression of tablet

 

6. Screening of dry granules

 

 

7. Blending with lubricant and disintegrant to produce “running powder”

 

 

8. Compression of tablet

 

 

Dispensing

(weighing and measuring)

Dispensing is the first step in any pharmaceutical manufacturing process. Dispensing is one of the most critical steps in pharmaceutical manufacturing; as during this step, the weight of each ingredient in the mixture is determined according to dose.

Dispensing may be done by purely manual by hand scooping from primary containers and weighing each ingredient by hand on a weigh scale, manual weighing with material lifting assistance like Vacuum transfer and Bag lifters, manual or assisted transfer with automated weighing on weigh table, manual or assisted filling of loss-in weight dispensing system, automated dispensaries with mechanical devices such as vacuum loading system and screw feed system.

Issues like weighing accuracy, dust control (laminar air flow booths, glove boxes), during manual handling, lot control of each ingredient, material movement into and out of dispensary should be considered during dispensing.

Sizing

The sizing (size reduction, milling, crushing, grinding, pulverization) is an impotent step (unit operation) involved in the tablet manufacturing.

In manufacturing of compressed tablet, the mixing or blending of several solid ingredients of pharmaceuticals is easier and more uniform if the ingredients are approximately of same size. This provides a greater uniformity of dose. A fine particle size is essential in case of lubricant mixing with granules for its proper function.

Advantages associated with size reduction in tablet manufacture are as follows:

i) It increases surface area, which may enhance an active ingredient’s dissolution rate and hence bioavailability.

ii) Improved the tablet-to-tablet content uniformity by virtue of the increased number of particles per unit weight.

iii) Controlled particle size distribution of dry granulation or mix to promote better flow of mixture in tablet machine.

iv) Improved flow properties of raw materials.

v) Improved colour and/or active ingredient dispersion in tablet excipients.

vi) Uniformly sized wet granulation to promote uniform drying.There are also certain disadvantages associated with this unit

operation if not controlled properly. They are as follows:

i) A possible change in polymorphic form of the active ingredient, rendering it less or totally inactive, or unstable.

ii) A decrease in bulk density of active compound and/or excipients, which may cause flow problem and segregation in the mix.

iii) An increase in surface area from size reduction may promote the adsorption of air, which may inhibit wettability of the drug to the extent that it becomes the limiting factor in dissolution rate.

A number of different types of machine may be used for the dry sizing or milling process depending on whether gentle screening or particle milling is needed. The ranges of equipment employed for this process includes Fluid energy mill, Colloidal mill, Ball mill, Hammer mill, Cutting mill, Roller mill, Conical mill, etc.

Powder blending

The successful mixing of powder is acknowledged to be more difficult unit operation because, unlike the situation with liquid, perfect homogeneity is practically unattainable.

In practice, problems also arise because of the inherent cohesiveness and resistance to movement between the individual particles. The process is further complicated in many system, by the presence of substantial segregation influencing the powder mix. They arise because of difference in size, shape, and density of the component particles.

The powder/granules blending are involved at stage of pre granulation and/or post granulation stage of tablet manufacturing. Each process of mixing has optimum mixing time and so prolonged mixing may result in an undesired product. So, the optimum mixing time and mixing speed are to be evaluated. Blending step prior to compression is normally achieved in a simple tumble blender. The Blender may be a fixed blender into which the powders are charged, blended and discharged. It is now common to use a bin blender which blends.

In special cases of mixing a lubricant, over mixing should be particularly monitered.

The various blenders used include “V” blender, Oblicone blender, Container blender, Tumbling blender, Agitated powder blender, etc.

But now a days to optimize the manufacturing process particularly in wet granulation the various improved equipments which combines several of processing steps (mixing, granulation and/or drying) are used. They are “Mixer granulator” or “High shear mixing machine”.

Granulation

Following particle size reduction and blending, the formulation may be granulated, which provides homogeneity of drug distribution in blend.

Drying

Drying is a most important step in the formulation and development of pharmaceutical product. It is important to keep the residual moisture low enough to prevent product deterioration and ensure free flowing properties. The commonly used dryer includes Fluidized ÃÃÃÃÃ