Tablet production involves various steps, and each can present unique processing problems. Below are some common issues encountered during tablet manufacturing and their suitable remedies:

1. Capping and Lamination

  • Problem: The tablet splits into two or more layers, often due to air entrapment.
  • Causes:
    • Improper binder usage
    • High speed of compression
    • Low moisture content
  • Remedies:
    • Optimize binder concentration
    • Adjust compression speed and pressure
    • Increase tablet moisture to enhance cohesion

2. Sticking and Picking

  • Problem: Material adheres to the tablet punches or the die, causing surface imperfections.
  • Causes:
    • Excessive moisture content
    • Low melting point of excipients
    • Improper lubrication
  • Remedies:
    • Dry granules properly to reduce moisture
    • Optimize formulation to reduce tackiness
    • Use anti-adherent agents like magnesium stearate

3. Chipping

  • Problem: Tablet edges break or chip during handling.
  • Causes:
    • High compression speed
    • Poor tooling condition
    • Insufficient binder
  • Remedies:
    • Reduce compression speed
    • Use high-quality punches and dies
    • Adjust binder concentration to improve tablet strength

4. Weight Variation

  • Problem: Tablets do not have consistent weights, leading to content uniformity issues.
  • Causes:
    • Uneven flow of granules
    • Improper feed mechanism
  • Remedies:
    • Improve powder flow properties with glidants
    • Ensure proper functioning of the feed mechanism
    • Calibrate the tablet press frequently

5. Mottling

  • Problem: Uneven color distribution on the tablet surface.
  • Causes:
    • Use of colored excipients or inadequate mixing
    • Migration of dye during drying
  • Remedies:
    • Use color-compatible excipients
    • Improve mixing to achieve uniform distribution
    • Adjust drying conditions to prevent color migration

6. Tablet Hardness Variation

  • Problem: Tablets have inconsistent hardness, which affects dissolution and friability.
  • Causes:
    • Inconsistent granule size
    • Variation in compression force
  • Remedies:
    • Granulate powder uniformly to ensure consistent particle size
    • Maintain constant compression force during tablet pressing

7. Friability

  • Problem: Tablets break easily, resulting in poor mechanical strength.
  • Causes:
    • Low compression force
    • Improper binder usage
  • Remedies:
    • Increase compression force to improve cohesion
    • Use an adequate binder to ensure tablet robustness

8. Tablet Sticking to Die and Punches (Filming)

  • Problem: Tablet material adheres to the punch faces, forming a film.
  • Causes:
    • Too much moisture or oily materials in formulation
    • High tablet compression temperature
  • Remedies:
    • Reduce the formulation’s moisture content
    • Use punch polishers or anti-adherent coatings

9. Double Impression

  • Problem: Tablets display a duplicate impression of punch markings.
  • Causes:
    • Punches not being correctly aligned or excessive rebound after compression
  • Remedies:
    • Ensure proper punch alignment
    • Use anti-turning punch guides to maintain punch orientation

10. Binding or Granules Not Flowing Well

  • Problem: Material fails to flow properly into the die cavity, leading to inconsistent tablet production.
  • Causes:
    • Poor flow properties of granules
    • Electrostatic charge build-up
  • Remedies:
    • Add glidants like talc or colloidal silicon dioxide
    • Employ anti-static agents or equipment

Each of these remedies should be optimized based on specific formulation requirements and process conditions to achieve effective and consistent tablet quality.