In 1843, William Brockedon patented a tablet-pressing method, using pressure on powders or granules with tablet-shaped dies. Today, tablets are manufactured primarily through compression, a process that preserves the chemical properties of powder formulations. Compression remains the preferred method over molding due to its efficiency and consistency.
Direct Compression in Pharmaceutical Tablets
Pharmaceutical companies worldwide use direct compression to produce tablets from dry or wet granules. Dry granulation forms granules without liquid solutions, ideal for moisture-sensitive or heat-sensitive materials. Wet granulation, on the other hand, uses binder solvents to create adhesion in powder blends. Tablets vary in color, shape, size, and dissolution characteristics, making them versatile for various therapeutic applications. Due to their convenience and flexibility, 90% of clinical pharmaceuticals are available in tablet form, primarily for oral use.
Developing Effective Active Ingredients
Creating effective active ingredients requires research into compound characteristics. Particle research investigates molecular interactions, stability, and binding abilities. By understanding these factors, formulators design stable, therapeutic drugs with targeted effects. Tablets also include excipients to enhance cohesion and fabrication, such as cellulose, lactose, stearates, and flavoring agents. Excipients support tablet integrity and improve the patient experience, whether by adjusting flavor, color, or texture.
Compression Techniques for Tablet Production
Proper granulation is essential to streamline the compression process. The most common methods, direct compression and granulation, both improve tablet cohesion. Direct compression uses binders that compress directly, while granulation involves wet or dry binding agents. Liquid binders are often more effective, but milling and mixing processes must also optimize powder flow, reduce segregation, and ensure even particle blending. In tablet presses, the formulated powder is compressed within a die, forming tablets with precision and consistency. This process works in tandem with automated feeders, weighing, dusting, coating, and packaging machines to maintain efficient production.
Common Defects in Tablet Compression
While compression offers speed and cost-effectiveness, tablet manufacturing requires careful attention to avoid defects. Many factors influence uniformity, bioavailability, and stability. Incomplete granulation, for instance, can cause shape defects, increase downtime, and raise production costs. Other issues may include weight inconsistencies, chipping, friability, capping, and laminating. Dry granulation can also produce softer tablets than wet granulation, which affects hardness and coating application. By addressing these challenges, manufacturers ensure tablet quality and reduce waste.
Storage and Packaging Essentials
Proper storage is crucial for tablet stability, especially for moisture-sensitive formulas. Desiccant packets or blister strip packaging protect tablets from humidity. Blister strips are widely used for their convenience and clear visibility of contents. Ideal storage conditions include low humidity, no direct sunlight, and moderate temperatures. Packaging provides environmental protection, helping tablets remain stable for years.
Quality control at the final manufacturing stage tests tablets to withstand compression, packaging, and user handling. Each batch undergoes rigorous inspection to verify potency, weight, consistency, and disintegration time, ensuring compliance with safety and health standards.
The Future of Tablets: Innovations in Medicine
Researchers are exploring new technologies to enhance tablet administration. Future advancements include mRNA treatments, micro-tablets, multi-layered tablets, and medicines with embedded biochips that communicate with healthcare providers. These biochips may track medication performance and ensure patient compliance. 3D printing also shows promise for personalized precision medicines. Powder technology plays a key role in modifying particles to suit these emerging applications, promising an exciting future for particle technology.