Tablet Edge Chipping/Erosion

The edges of the tablets are worn away, or chipped, as the coating is being applied.

ISSUE CAUSES RECOMMENDATIONS
Tablet Core Tablet tooling is worn or damaged. Learn more.
  • Refurbish or replace damaged/worn punches.
Tablet edges are too sharp.
  • Select different tablet core design, (e.g., use compound radius punches) to minimize tablet edges. Learn more.
Tablet robustness (friability) is not optimal for a stressful process such as film coating.
  • Consider reformulating core, (e.g., addition of a more plastic binder such as hydroxypropyl cellulose) to reduce brittleness and increase robustness. Learn more.
  • Increase compaction forces to reduce tablet friability.
Coating Formulation Formulation has insufficient film strength to provide increased resistance to edge damage.
  • Consult with Ashland to select an Aquarius™ film coating system with increased mechanical strength and/or increased film flexibility.
Coating cannot be applied fast enough to allow coating build-up to protect edges.
  • Consult with Ashland to select an Aquarius film coating system that can be sprayed at higher solids.
Coating Process Pan speed too high, causing increased edge wear.
  • Reduce pan speed throughout process.
  • Reduce pan speed initially until sufficient coating has been applied to increase core robustness, and then speed up pan to normal speed.
  • Do not pre-warm tablets, but start spraying once correct inlet temperature has been reached. This reduces damage during the pre-warming.
  • Pre-warm tablets to higher temperature so coating can be applied faster. Learn more.
Pan is under loaded.
  • Ensure pan is loaded to optimal fill weight.
Baffles are causing excessive damage to tablets.
  • Consult with equipment vendor to see if an alternative baffle design is available.