Troubleshooting Guide – TOP 10 Tableting Errors

Possible reasons and remedies for top 10 common tablet defects.

Lots of parameters have to be considered before and during a tableting process. Sometimes it is necessary to adjust parameters in order to achieve the best possible results. But do you always know which modifications are needed to improve the process? Has the problem been caused by the machine, tablet mass or both?

There are a lot of factors that can lead to a suboptimal result. The tablet core may become too soft or show high abrasion. Incorrect process parameters, such as too fast press speed or filling time or too low or high pressure also lead to defects.

This Troubleshooting Guide shows the most common tablet defects that can be avoided easily. It helps you find the best way to achieve perfect results. Furthermore, we provide on-site technical services for our customers and help in the research for new solutions.

Common Challenges in Tableting:

Problem 1: Capping / Lamination

Possible reason:

• Too many fine particles in the granulate
• Separation of the granulate
• Too much of hydrophobic lubricant
• No suitable lubricant
• Not enough or not suitable binder
• Low moisture content
• API content too high
• Compression force too high
• Speed of the tablet press too high
• Too much air trapped in the pre-compression
• Tablet press tool defective

Remedy:?

• Change the quantities in the granulate
• Use enough and an efficient binding agent
• Adjust used lubricant
• Add adsorbent agent
• Moisturize or dry the granulates
• Reduce amount of API
• Adjust the pressure for compression (use pre-compression)
• Decrease speed of the tablet press
• Use more suitable punches (conical)

Problem 2: Sticking to punches

Possible reason:

• The granulate was not completely dried
• Lubricant content too low
• Too much binder used
• Oily or waxy materials used
• Too soft or weak granulates
• Compression too high or too low
• The product became too warm
• Rough or scratched punch faces

Remedy:

• Completely dry the granulate
• Use enough and an efficient lubricant
• Add suitable binder
• Modify mixing process and add an absorbent
• Adjust the compression force
• Produce a thinner tablet (height)
• Polish the surface of the punch

Problem 3: Cracking

Possible reason:

• The granulate is too large
• The granulate is too dry
• Tablets expand
• Granulation too cold
• Tablet expands on ejection due to air entrapment

Remedy:

• Reduce granulate size by adding more fine particles
• Moisturize or dry the granulate and add binder
• Improve granulation, add dry binders
• Adjust ambient temperature
• Use conical die

Find more problems and remedies at our poster. For example how to deal with these challenges: Chipping, Binding, Weight variations, tablet hardness and friability.

Here is the poster download: https://www.biogrund.com/top-10-troubleshooting-guide-tablettierung/biogrund-troubleguide_tableting-2/

Contact us for sending DIN A1 hard copy posters for your lab or production – free of charge.

Troubleshooting in tableting is an integral aspect of ensuring product quality and process efficiency in pharmaceutical, nutraceutical and general SODFs manufacturing. By understanding common challenges and employing systematic troubleshooting strategies, manufacturers can address issues promptly, optimize the tableting process, and ultimately produce high-quality tablets. Regular monitoring, collaboration, and a commitment to continuous improvement are key elements in successfully navigating the challenges inherent in tableting.

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