Peerapattana Peerapattana Faculty of Faculty of Pharmaceutical Pharmaceutical Sciences Sciences Khon Kaen University Khon Kaen University Scope Scope Introduction Introduction Advantages and Advantages and disadvantages of disadvantages of compressed tabIets compressed tabIets Types of tabIets Types of tabIets TabIet compression TabIet compression machine machine TabIeting methods TabIeting methods 397oduc9o3 397oduc9o3 1843 1843 a patent was granted to a patent was granted to Thomas Brockedon Thomas Brockedon (EngIishman) for (EngIishman) for manufacturing piIIs and manufacturing piIIs and Iozenges Iozenges 1874 1874 both rotary and both rotary and eccentric presses eccentric presses 1885 1885 gIyceryI trinitrate gIyceryI trinitrate tabIets was in the BP tabIets was in the BP dva39ages dva39ages Production aspect Production aspect arge scaIe production at Iowest arge scaIe production at Iowest cost cost Easiest and cheapest to package Easiest and cheapest to package and ship and ship High stabiIity High stabiIity User aspect (doctor, pharmacist, User aspect (doctor, pharmacist, patient) patient) Easy to handIing Easy to handIing ightest and most compact ightest and most compact Greatest dose precision & Ieast Greatest dose precision & Ieast Disadvantages Disadvantages $ome drugs resist $ome drugs resist compression into dense compression into dense compacts compacts Drugs with Drugs with poor wetting, sIow poor wetting, sIow dissoIution, intermediate to dissoIution, intermediate to Iarge dosages Iarge dosages may be difficuIt may be difficuIt or impossibIe to formuIate and or impossibIe to formuIate and manufacture as a tabIet that manufacture as a tabIet that provide adequate or fuII drug provide adequate or fuII drug bioavaiIabiIity bioavaiIabiIity Bitter taste drugs, drugs with Bitter taste drugs, drugs with Absorpti Absorpti on of on of drug drug form form tablets tablets 3g7ede39s used 3 3g7ede39s used 3 9able9 fo72ula9o3s 9able9 fo72ula9o3s Drugs Drugs FiIIers, diIuent, buIking agent FiIIers, diIuent, buIking agent To make a reasonabIy sized To make a reasonabIy sized tabIet tabIet Binders Binders To bind powders together in To bind powders together in the wet granuIation process the wet granuIation process To bind granuIe together To bind granuIe together during compression during compression Disintegrants Disintegrants To promote breakup of the To promote breakup of the tabIets tabIets ubricants ubricants To reduce the friction during To reduce the friction during tabIet ejection between the waIIs tabIet ejection between the waIIs of the tabIet and the waIIs of the of the tabIet and the waIIs of the die cavity die cavity GIidants GIidants Reducing friction between the Reducing friction between the particIes particIes To improve the fIow properties of To improve the fIow properties of the granuIations the granuIations Antiadherants Antiadherants To prevent adherence of the To prevent adherence of the DissoIution (enhancers and DissoIution (enhancers and retardants) retardants) Wetting agents Wetting agents Antioxidants Antioxidants Preservatives Preservatives CoIoring agents CoIoring agents FIavoring agents FIavoring agents ssential properties ssential properties of tablets of tablets Accurate dosage Accurate dosage of of medicament, uniform in weight, medicament, uniform in weight, appearance and diameter appearance and diameter Have the Have the strength strength to withstand to withstand the rigors of mechanicaI the rigors of mechanicaI shocks encountered in its shocks encountered in its production, packaging, production, packaging, shipping and dispensing shipping and dispensing ReIease ReIease the medicinaI agents in the medicinaI agents in the body in a predictabIe and the body in a predictabIe and reproducibIe manner reproducibIe manner %ypes of tablets %ypes of tablets Route of administration Route of administration raI tabIets raI tabIets $ubIinguaI or buccaI tabIets $ubIinguaI or buccaI tabIets VaginaI tabIets VaginaI tabIets Production process Production process Compressed tabIets Compressed tabIets MuItipIe compressed tabIets MuItipIe compressed tabIets TabIet within a tabIets: core TabIet within a tabIets: core and sheII and sheII MuItiIayer tabIet MuItiIayer tabIet $ugar coated tabIets $ugar coated tabIets Protect tabIets from Protect tabIets from moisture moisture Mask odor and fIavor Mask odor and fIavor EIegance EIegance FiIm coated tabIets FiIm coated tabIets Thin fiIm coat Thin fiIm coat $oIubIe or insoIubIe $oIubIe or insoIubIe ChewabIe tabIets ChewabIe tabIets Rapid disintegrate Rapid disintegrate Antacid, fIatuIance: rapid Antacid, fIatuIance: rapid action action ChiIdren drug ChiIdren drug Effervescent tabIets Effervescent tabIets DissoIve in the water DissoIve in the water before drink before drink %ablet production %ablet production Powders intended for Powders intended for compression into tabIets compression into tabIets must possess two essentiaI must possess two essentiaI properties properties Powder fIuidity Powder fIuidity The materiaI can be The materiaI can be transported through the transported through the hopper into the die hopper into the die To produce tabIets of a To produce tabIets of a Powder compressibiIity Powder compressibiIity The property of forming a The property of forming a stable, intact compact mass stable, intact compact mass when pressure is applied when pressure is applied %able93g p7ocedu7e %able93g p7ocedu7e Filling Filling Compression Compression Ejection Ejection %ablet compression %ablet compression machines machines Hopper Hopper for holding and feeding for holding and feeding granulation to be compressed granulation to be compressed Dies Dies that define the size and that define the size and shape of the tablet shape of the tablet Punches Punches for compressing the for compressing the granulation within the dies granulation within the dies Cam tracks Cam tracks for guiding the for guiding the movement of the punches movement of the punches Feeding mechanisms Feeding mechanisms for moving for moving Single punch Single punch machine machine The compression is applied The compression is applied by the upper punch by the upper punch Stamping press Stamping press Upper and Lower Collar Collar locker $ingIe Punch Machine (TabIets) ulti ulti- -station rotary station rotary presses presses The head of the tabIet machine The head of the tabIet machine that hoIds the upper punches, that hoIds the upper punches, dies and Iower punches in dies and Iower punches in pIace rotates pIace rotates As the head rotates, the As the head rotates, the punches are guided up and punches are guided up and down by fixed cam tracks, down by fixed cam tracks, which controI the sequence of which controI the sequence of fiIIing, compression and fiIIing, compression and ejection. ejection. The portion hoIding the dies is The portion hoIding the dies is caIIed the caIIed the die tabIe die tabIe The The puII down cam (C) puII down cam (C) guides guides the Iower punches to the the Iower punches to the bottom, aIIowing the dies to bottom, aIIowing the dies to overfiII overfiII The punches then pass over a The punches then pass over a weight weight- -controI cam (E), controI cam (E), which which reduces the fiII in the dies to reduces the fiII in the dies to the desired amount the desired amount A A swipe off bIade (D) swipe off bIade (D) at the end at the end of the feed frame removes the of the feed frame removes the excess granuIation and directs excess granuIation and directs it around the turret and back it around the turret and back into the front of the feed frame into the front of the feed frame The Iower punches traveI over The Iower punches traveI over the the Iower compression roII (F) Iower compression roII (F) whiIe simuItaneousIy the upper whiIe simuItaneousIy the upper punches ride beneath the punches ride beneath the upper upper The upper punches enter a The upper punches enter a fixed distance into the dies, fixed distance into the dies, whiIe the Iower punches are whiIe the Iower punches are raised to squeeze and compact raised to squeeze and compact the granuIation within the dies the granuIation within the dies After the moment of After the moment of compression, the upper compression, the upper punches are withdrawn as they punches are withdrawn as they foIIow the foIIow the upper punch raising upper punch raising The tabIets strike a sweep off The tabIets strike a sweep off bIade affixed to the front of the bIade affixed to the front of the feed frame (A) feed frame (A) and sIide down a and sIide down a chute into a receptacIe chute into a receptacIe At the same time, the Iower At the same time, the Iower punches re punches re- -enter the enter the puII down puII down cam (C) cam (C) and the cycIe is and the cycIe is repeated repeated AIthough tabIet compressing AIthough tabIet compressing machinery has undergone machinery has undergone numerous mechanicaI numerous mechanicaI modifications over the years, modifications over the years, the compaction of materiaIs the compaction of materiaIs between a pair of moving between a pair of moving punches within a stationary die punches within a stationary die has has remained unchanged remained unchanged The principIe modification from The principIe modification from earIier equipment has been an earIier equipment has been an increase in production rate increase in production rate which is reguIated by which is reguIated by $peciaI adaptations of tabIet $peciaI adaptations of tabIet machines aIIow for the machines aIIow for the compression of Iayered tabIets compression of Iayered tabIets and coated tabIets and coated tabIets A device that chiIIs the A device that chiIIs the compression components to compression components to aIIow for the compression of aIIow for the compression of Iow Iow- -meIting point substances meIting point substances such as waxes i.e. such as waxes i.e. %ableting methods %ableting methods Dry methods Dry methods Direct compression Direct compression Dry granuIation Dry granuIation Wet methods Wet methods Wet granuIation Wet granuIation Direct compression Direct compression TabIets are compressed TabIets are compressed directIy from powder bIends of directIy from powder bIends of the active ingredient and the active ingredient and suitabIe excipients suitabIe excipients No pretreatment of the powder No pretreatment of the powder bIends by wet or dry bIends by wet or dry granuIation procedures is granuIation procedures is necessary necessary Advantages Advantages Economy Economy Machine: fewer Machine: fewer manufacturing steps and manufacturing steps and pieces of equipment pieces of equipment abor: reduce Iabor costs abor: reduce Iabor costs ess process vaIIidation ess process vaIIidation ower consumption of ower consumption of power power EIimination of granuIation EIimination of granuIation process process Heat (wet granuIation) Heat (wet granuIation) Moisture (wet granuIation) Moisture (wet granuIation) High pressure (dry High pressure (dry granuIation) granuIation) Processing without the need Processing without the need for moisture and heat which for moisture and heat which is inherent in most wet is inherent in most wet Avoidance of high Avoidance of high compaction pressures compaction pressures invoIves in producing invoIves in producing tabIets by sIugging or roII tabIets by sIugging or roII compaction compaction EIimination of variabiIities EIimination of variabiIities in wet granuIation in wet granuIation processing processing Binders (temp, viscous, Binders (temp, viscous, age) age) Viscosity of the granuIating Viscosity of the granuIating Rate of binder addition and Rate of binder addition and kneading can affect the kneading can affect the properties of the granuIes properties of the granuIes formed formed The granuIating soIution, the The granuIating soIution, the type and Iength of mixing type and Iength of mixing and the method and rate of and the method and rate of wet and dry screening can wet and dry screening can change the density and change the density and particIe size of the granuIes, particIe size of the granuIes, which can have a major which can have a major Type and rate of drying Type and rate of drying can Iead not onIy to criticaI can Iead not onIy to criticaI changes in equiIibrium MC but changes in equiIibrium MC but aIso to unbIending as soIubIe aIso to unbIending as soIubIe active ingredients migrate to active ingredients migrate to the surfaces of the drying the surfaces of the drying granuIes granuIes More unit processes are More unit processes are incorporated in production, incorporated in production, the chances of batch the chances of batch- -to to- -batch batch Prime particIe Prime particIe dissociation dissociation Each primary drug Each primary drug particIe is Iiberated from particIe is Iiberated from the tabIet mass and is the tabIet mass and is avaiIabIe for dissoIution avaiIabIe for dissoIution Disintegrate rapidIy to Disintegrate rapidIy to the primary particIe state the primary particIe state Uniformity of particIe Uniformity of particIe size size Greater stabiIity of tabIet Greater stabiIity of tabIet on aging on aging CoIor CoIor DissoIution rate DissoIution rate Fewer chemicaI stabiIity Fewer chemicaI stabiIity probIems wouId be probIems wouId be encountered as encountered as Concerns Concerns Excipient avaiIabIe from Excipient avaiIabIe from onIy one suppIier and onIy one suppIier and often cost more than often cost more than fiIIer used in granuIation fiIIer used in granuIation Procedure conservation Procedure conservation Machine investments Machine investments ack of materiaI ack of materiaI knowIedge knowIedge PhysicaI Iimitation of drug PhysicaI Iimitation of drug No compressibiIity No compressibiIity No fIowabiIity No fIowabiIity PhysicaI characteristics of PhysicaI characteristics of materiaIs (both drug and materiaIs (both drug and excipient) excipient) $ize and size distribution $ize and size distribution Moisture Moisture $hape and surface $hape and surface FIowabiIity FIowabiIity Density Density ot to Iot variabiIity ot to Iot variabiIity Dusting probIem Dusting probIem CoIoring CoIoring 7ec9 co2p7esso3 7ec9 co2p7esso3 flle7s flle7s Common materiaIs that Common materiaIs that have been modified in the have been modified in the chemicaI manufacturing chemicaI manufacturing process to improve fIuidity process to improve fIuidity and compressibiIity and compressibiIity Soluble flle7s Soluble flle7s actose actose $pray dried Iactose $pray dried Iactose actose is pIaced in actose is pIaced in aqueous soIution, removed aqueous soIution, removed impurities and spray dried impurities and spray dried Mixture of Iarge aIpha Mixture of Iarge aIpha monohydrate crystaIs and monohydrate crystaIs and sphericaI aggregates of sphericaI aggregates of smaIIer crystaIs smaIIer crystaIs Good fIowabiIity but Iess Good fIowabiIity but Iess oss compressibiIity upon oss compressibiIity upon initiaI compaction initiaI compaction ProbIem of browning due ProbIem of browning due to contamination of to contamination of 5 5- - hydroxyfurfuraI which was hydroxyfurfuraI which was acceIerated in the acceIerated in the presence of basic amine presence of basic amine drugs and cataIyzed by drugs and cataIyzed by tartrate, citrate and acetate tartrate, citrate and acetate Fast Fast- -FIo Iactose (earIy FIo Iactose (earIy 1970 1970s) s) $phericaI aggregates of $phericaI aggregates of microcrystaIs Iactose microcrystaIs Iactose monohydrate monohydrate HeId together by a higher HeId together by a higher concentration of gIass concentration of gIass (amorphous Iactose) (amorphous Iactose) Much more compressibIe Much more compressibIe HighIy fIuid HighIy fIuid Non hygroscopic Non hygroscopic TabIets are three to four TabIets are three to four times harder than reguIar times harder than reguIar spray dried spray dried TabIetose: aggromerate form TabIetose: aggromerate form of Iactose of Iactose More compressibIe than More compressibIe than spray dried but Iess spray dried but Iess compressibIe than Fast FIo compressibIe than Fast FIo Iactose Iactose Anhydrous Iactose: free Anhydrous Iactose: free fIowing crystaIIine Iactose fIowing crystaIIine Iactose Produced by crystaIIization Produced by crystaIIization above above 93 93C which produces C which produces the beta form the beta form Pass through steam heated Pass through steam heated roIIers roIIers Good fIow property, Good fIow property, contained high amount of contained high amount of fines, its fIuidity is Iess than fines, its fIuidity is Iess than optimaI optimaI At high RH anhydrous At high RH anhydrous Iactose wiII pick up Iactose wiII pick up moisture forming the moisture forming the hydrated compound hydrated compound increase in the size of increase in the size of tabIets if the excipient tabIets if the excipient makes up a Iarge portion of makes up a Iarge portion of the totaI tabIet weight the totaI tabIet weight ExceIIent dissoIution ExceIIent dissoIution $ucrose $ucrose Di Di- -Pac: cocrystaIIization of Pac: cocrystaIIization of 97 97% sucrose and % sucrose and 3 3% modified % modified dextrin dextrin $maII sucrose crystaIs $maII sucrose crystaIs gIued together by dextrin gIued together by dextrin Good fIow properties and Good fIow properties and needs a gIidant onIy when needs a gIidant onIy when atmospheric moisture IeveIs atmospheric moisture IeveIs are high (> are high (>50 50%RH) %RH) Concentration of moisture Concentration of moisture is extremeIy criticaI in is extremeIy criticaI in terms of product terms of product compressibiIity compressibiIity compressibiIity increases compressibiIity increases rapidIy in a moisture range rapidIy in a moisture range of of 0 0..3 3- -0 0..4 4%, pIateaus at a %, pIateaus at a IeveI of IeveI of 0 0..4 4- -0 0..5 5% and rises % and rises again rapidIy up to again rapidIy up to 0 0..8 8% % when the product begins when the product begins DiIution potentiaI DiIution potentiaI 20 20- -35 35% % TabIets tend to harden TabIets tend to harden sIightIy during the first sIightIy during the first hours after compression or hours after compression or when aged at high when aged at high humidities and then dried humidities and then dried (this is typicaI of most direct (this is typicaI of most direct compression sucroses or compression sucroses or dextroses) dextroses) Nutab: Nutab: 95 95..8 8% sucrose, % sucrose, 4 4% % convert sugar (equimoIecuIar convert sugar (equimoIecuIar mixture of IevuIose and mixture of IevuIose and dextrose) and dextrose) and 0 0..1 1 to to 0 0..2 2% % each of cornstarch and each of cornstarch and magnesium strarate magnesium strarate arge particIe size arge particIe size distribution and good distribution and good fIuidity fIuidity Poor coIor stabiIity Poor coIor stabiIity Dextrose Dextrose Emdex: spray crystaIIized Emdex: spray crystaIIized 90 90- -92 92% dextrose, % dextrose, 3 3- -5 5% % maItose and the remainder maItose and the remainder higher gIucose higher gIucose poIysaccharides poIysaccharides AvaiIabIe both anhydrous AvaiIabIe both anhydrous and a hydrate product and a hydrate product ExceIIent compressibiIity ExceIIent compressibiIity argest particIe size, argest particIe size, bIending probIem may bIending probIem may $orbitoI $orbitoI Exists in a number of Exists in a number of poIymorphic crystaIIine forms poIymorphic crystaIIine forms and amorphous form and amorphous form WideIy used in sugar WideIy used in sugar- -free free mints and as a vehicIe in mints and as a vehicIe in chewabIe tabIets chewabIe tabIets CooI taste and good mouth CooI taste and good mouth feeI feeI Forms a hard compact Forms a hard compact Hygroscopic and wiII cIump Hygroscopic and wiII cIump in the feed frame and stick to in the feed frame and stick to the surfaces of the die tabIe the surfaces of the die tabIe when tabIeted at humidities > when tabIeted at humidities > 50 50% % ubricant requirements ubricant requirements increase when the MC of the increase when the MC of the sorbitoI drops beIow sorbitoI drops beIow 0 0..5 5% or % or exceeds exceeds 2 2% % MannitoI MannitoI Exists in a number of Exists in a number of poIymorphic forms poIymorphic forms Not make as hard a tabIet as Not make as hard a tabIet as sorbitoI sorbitoI ess sensitive to humidity ess sensitive to humidity WideIy used where rapid and WideIy used where rapid and compIete soIubiIity is compIete soIubiIity is required required Use as a fiIIer in chewabIe Use as a fiIIer in chewabIe MaItodextrin MaItodextrin MaItrin MaItrin HighIy compressibIe HighIy compressibIe CompIeteIy soIubIe CompIeteIy soIubIe Very Iow hygroscopic Very Iow hygroscopic 3soluble flle7s 3soluble flle7s $tarch $tarch $tarch $tarch 1500 1500: intact starch : intact starch grains and ruptured starch grains and ruptured starch grains that have been grains that have been partiaIIy hydroIyzed and partiaIIy hydroIyzed and subsequentIy aggromerated subsequentIy aggromerated ExtremeIy high MC ( ExtremeIy high MC (12 12- -13 13%) %) Does not form hard Does not form hard compacts compacts DiIution potentiaI is minimaI DiIution potentiaI is minimaI Not generaIIy used as fiIIer Not generaIIy used as fiIIer- - binder but as fiIIer binder but as fiIIer disintegrant disintegrant Retains the disintegrant Retains the disintegrant properties of starch without properties of starch without increasing the fIuidity and increasing the fIuidity and compressibiIity of the totaI compressibiIity of the totaI formuIation formuIation Deforms eIasticaIIy when a Deforms eIasticaIIy when a compression force is appIied, compression force is appIied, it imparts IittIe strength to it imparts IittIe strength to compacts compacts $pray dried starch $pray dried starch Era Era- -Tab: spray Tab: spray- -dried rice dried rice starch starch Good fIuidity Good fIuidity MC MC 10 10- -13 13% % CompressibiIity depend CompressibiIity depend on moisture on moisture ReworkabiIity ReworkabiIity ow buIk density ow buIk density CeIuIose CeIuIose MicrocrystaIIine ceIIuIose MicrocrystaIIine ceIIuIose (AviceI) (AviceI) The most important tabIet The most important tabIet excipient deveIoped in excipient deveIoped in modern times modern times Derived from a speciaI Derived from a speciaI grade of purified aIpha grade of purified aIpha wood ceIIuIose by severe wood ceIIuIose by severe acid hydroIysis to remove acid hydroIysis to remove the amorphous ceIIuIose the amorphous ceIIuIose portions, yieIding particIes portions, yieIding particIes PH PH101 101 powder powder PH PH102 102 more aggIomerated, more aggIomerated, Iarger particIe size, sIightIy Iarger particIe size, sIightIy better fIuidity but not better fIuidity but not significant decrease in significant decrease in compressibiIity compressibiIity Most compressibIe Most compressibIe Highest diIution potentiaI Highest diIution potentiaI A strong compact is formed A strong compact is formed due to the extremeIy Iarge due to the extremeIy Iarge number of cIean surfaces number of cIean surfaces brought in contact during brought in contact during the pIastic deformation and the pIastic deformation and the strength of the the strength of the hydrogen bonds formed hydrogen bonds formed ExtremeIy Iow coefficient of ExtremeIy Iow coefficient of friction, no Iubricant friction, no Iubricant requirement requirement When > When >20 20% of drugs or % of drugs or other excipients are added, other excipients are added, Not used as the onIy fiIIer Not used as the onIy fiIIer because of its cost and because of its cost and density density UsuaIIy used in the conc of UsuaIIy used in the conc of 10 10- -25 25% as a fiIIer % as a fiIIer- -binder binder- - disintegrant, rapid passage disintegrant, rapid passage of water into the compact of water into the compact and the instantaneous and the instantaneous rupture of hydrogen bonds rupture of hydrogen bonds FIuidity is poor because of FIuidity is poor because of its reIativeIy smaII particIe its reIativeIy smaII particIe size, smaII amount of size, smaII amount of gIidant are recommended in gIidant are recommended in the formuIations containing the formuIations containing high conc of MCC high conc of MCC TabIets are soften on TabIets are soften on exposure to high humidities exposure to high humidities This softening is reversibIe This softening is reversibIe when tabIets are removed when tabIets are removed from the humid environment from the humid environment >>80 80% MCC may sIow the % MCC may sIow the dissoIution rates of AI dissoIution rates of AI $maII particIes get $maII particIes get physicaIIy trapped between physicaIIy trapped between the deformed MCC particIes, the deformed MCC particIes, which deIays wetting and which deIays wetting and dissoIution dissoIution This phenomenon can be This phenomenon can be overcome by adding overcome by adding portions of water soIubIe portions of water soIubIe excipient excipient Inorganic caIcium saIts Inorganic caIcium saIts DicaIcium phosphate DicaIcium phosphate (Emcompress or DiTab) (Emcompress or DiTab) Free fIowing aggregates of Free fIowing aggregates of smaII microcrystaIs that smaII microcrystaIs that shatter upon compaction shatter upon compaction Inexpensive and possesses Inexpensive and possesses a high degree of physicaI a high degree of physicaI and chemicaI stabiIity and chemicaI stabiIity Nonhygroscopic at a RH of Nonhygroscopic at a RH of $IightIy aIkaIine with a pH of $IightIy aIkaIine with a pH of 7 7..0 0 to to 7 7..3 3 PrecIudes its use with AI PrecIudes its use with AI that are sensitive to even that are sensitive to even minimaI amounts of minimaI amounts of aIkaIinity aIkaIinity TricaIcium phosphate (TriTab) TricaIcium phosphate (TriTab) is Iess compressibIe and Iess is Iess compressibIe and Iess soIubIe, higher ratio of soIubIe, higher ratio of #eferences #eferences u|LM u|LM ( (L L..LvMn LvMn) ) Pharmaceutics. The science of Pharmaceutics. The science of dosage forms design. (M.E. dosage forms design. (M.E. AuIton) AuIton) The theory and practice of The theory and practice of industriaI pharmacy. industriaI pharmacy. PharmaceuticaI dosage forms PharmaceuticaI dosage forms : TabIets. VoIume : TabIets. VoIume 2 2.. PharmaceuticaI dosage forms PharmaceuticaI dosage forms