DT Pharmaceuticals - 3 | 25
REAL PROBLEMS, REAL SOLUTIONS
In tablet production, sticking—where particles of the formulation adhere to the face of the die or punch tip—is one of the biggest headaches. For many, this means:
-
Frequent press stoppages for cleaning;
-
Degradation of tablet appearance and quality;
-
Weight variation;
-
Reduced output and high production costs.
The good news is that I Holland has developed a set of robust and proven solutions to mitigate or even completely avoid this problem.
Main solutions offered by I Holland
-
PharmaCote – range of anti-stick treatments Special coatings applied to punches, designed to reduce granule adhesion. They not only reduce sticking, but also protect against wear and corrosion.
-
TSAR Predict (Tabletting Science Anti-Stick Research) A predictive model that allows you to identify which anti-stick coating from the PharmaCote range will be most effective for a specific formulation, without the need for extensive testing.
-
Evaluation of tablet morphology, surface finish, and design Checking the finish (roughness) of the punch face, creating profile molds, and changing the tablet design.
-
Environmental and process control External factors such as temperature, humidity, compression speed, or granule properties (moisture, dryness, static, elasticity/plasticity) have a direct impact on sticking. I Holland emphasizes that it is not just about the tool, but the entire process.
-
Tool maintenance and usage strategy Regular checks, replacement of tools or coatings when the tool/coating is nearing the end of its cycle, helping to take action before sticking becomes critical.
Success story
A good example: A pharmaceutical company was experiencing sticking and picking in a coated anti-epileptic tablet. After analyzing the formulation, tablet profile, and using the TSAR Predict model, I Holland recommended the use of PharmaCote CN+ coating, new punches/tips, and an improved design. Result: sticking/picking was eliminated, and production increased by ~25% without interruptions for cleaning.
Practical steps for solving sticking problems:
Collect data: API, excipients, physical form of the granules, compression conditions, humidity, temperature.
Involve the tool supplier from the outset so they can suggest coatings or design adjustments.
Use predictive models such as TSAR Predict to select suitable coatings.
Implement preventive maintenance measures, control the production environment.
Be aware of wear: using wear indication tools can prevent problems before they cause downtime.