What is a coating machines in pharma?

Tablet coating machines are pivotal in pharmaceutical production, serving not just to enhance the visual appeal of tablets but also to protect the active ingredients, mask unpleasant tastes, and control drug release. This dual role of aesthetic enhancement and functional protection underscores their value in the manufacturing process. In this blog, you will learn more about what a coating machine is, as well as the different types and advantages.

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Evolution of tablet coating techniques

The journey from traditional sugar coating to contemporary film coating reflects significant advancements in efficiency, functionality, and patient compliance. Sugarcoating, while effective for taste masking, was labor-intensive and time-consuming. The shift to polymer-based film coatings revolutionized the industry by offering thinner, more uniform coatings that could be tailored to achieve specific release mechanisms and improve drug stability.

Operational principles of tablet coating machines

Thus, what is a coating machine exactly? The core function of a tablet coating machine involves applying a uniform coating to tablets under controlled conditions. This process typically includes loading the tablets into the coating drum, spraying them with a coating solution, drying the tablets to fix the coating, and unloading them for packaging. Achieving a uniform coat requires precise control over the spray rate, drum speed, and drying temperature.

Types of tablet coating machines

There are several types of coating machines, each with its unique features and advantages. &#;

• &#;Pancoaters: Traditional machines of the tablet coating process, pan coaters rotate a pan or drum to tumble tablets while coating them with a spray solution. They are celebrated for their simplicity and effectiveness in batch processing.&#;
• Perforated drum coaters: An evolution of pan coaters, these machines feature a perforated drum that improves air flow and drying efficiency, leading to faster processing times and more consistent coatings.&#;
• Fluid bed coaters: Representing a significant technological leap, fluid bed coaters use a fluidization process to suspend tablets in air, allowing for even coating and efficient drying. This method is particularly suited for fine-tuning the coating process to achieve specific release profiles.

Advantages of modern tablet coating machines

The adoption of advanced tablet coating machines offers several compelling advantages:

• Efficiency: Enhanced processing speeds and automation reduce production times and labor costs.
• Consistency: Improved control mechanisms ensure uniform coating thickness and quality across batches.
• Versatility: Ability to accommodate a wide range of coating materials and tablet sizes. Explore the importance of qualitative pharmaceutical packaging materials.
• Compliance: Modern machines are designed to meet stringent regulatory standards for safety and quality.

Challenges in tablet coating

Despite technological advancements, tablet coating remains a complex process with inherent challenges:

• Uniformity: Achieving consistent coating thickness and quality across all tablets in a batch can be difficult.
• Adherence: Ensuring the coating material adheres properly to the tablet surface without causing defects requires precise control of the coating conditions, especially with today's wide array of tablets.
• Scalability: Transferring coating processes from pilot scale to full production scale without loss of quality demands thorough understanding and careful adjustment of process parameters.

Impact on controlled release and patient compliance

Coating technology is important in developing controlled-release formulations that deliver medication at the desired rate, improving therapeutic outcomes and patient adherence. Coatings can also be used to differentiate products, provide information, and improve the overall patient experience through enhanced visual appeal and taste masking.

Looking ahead: innovations in tablet coating technology

The future of tablet coating technology is marked by innovation, with ongoing research focusing on developing new coating materials, enhancing process control, and integrating smart technologies for real-time monitoring and optimization. These advancements promise to further improve the efficiency, flexibility, and environmental sustainability of tablet coating processes.

Conclusion: the role of tablet coating machines

Tablet coating machines play a crucial role in pharmaceutical manufacturing, combining aesthetics with essential functional benefits. As the industry keeps changing, these machines will remain at the forefront of technological advancements, driving improvements in drug delivery, patient compliance, and manufacturing efficiency. Their development reflects the pharmaceutical industry's ongoing commitment to quality, innovation, and patient care.

Also read: Why is there cotton in pill bottles?

Working Principle Of Auto Coater Machine

The auto coater consists of a control system, a hot air filtering system, coating pan, solution tank, and exhaust system. The film to be coated on the tablet is in liquid form before the process is started so the liquid is filled in the solution tank. The liquid is stirred well in the solution tank and then pumped into the coating pan. The coating pan is perforated and holds a batch of tablets that are to be coated. A set of spray guns are present at the center to spray the coating liquid on the tablets. The coating pan is able to rotate on its axis.

Hot air is passed in from a hot air blower which is passed through a series of filters to remove impurities. The filters used are a washable filter, pre-filter, and HEPA filter. The air from the blower is not hot initially so a steam heater is used to heat the air before passing it into the coating pan. The machine is operated by PLC controls from the control panel.

In the coating process, the tablets or similar products that are to be coated with film coating are filled in the coating pan. The coating liquid is pumped from the solution tank into the coating pan. The spray guns spray the tablets with atomized particles of

the coating solution as the perforated coating pan is rotated so that the entire batch of tablets is evenly coated. Simultaneously, the hot air from the blower is passed in to the drum at negative pressure which dries the sprayed coating evenly and rapidly which then causes it to become a solid and smooth surface film on each of the tablets.

The air is then exited from the perforated coating pan and moves to the exhaust system. The exhaust system consists of an exhaust blower to send the exit air from the coating pan to the external environment. The exhaust system consists of a dust collector which is also called a scrubber. In some systems, wet scrubbers are used to filter the particulates in the exhaust. The liquid droplets within the wet scrubber absorb the particulate matter thereby filtering the exhaust air before release.

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what is the auto coating?

Auto coater or automatic coating machine is an apparatus that is used to coat surfaces of small particles with a thin film of coating substance.

In pharmaceutical industries the auto coater is used to coat the tablets. The tablets are sprayed with a coating as the tablets move on in a device and then hot filtered air is passed so that the applied coat dries immediately to form a thin layer of coating on the tablet surface.

Coating

It is the application of coating solution to the rotating bed of tablets with the application of hot air to facilitate the evaporation.

OR

A compound or multiple layer over the tablet or granules is called coating.

Applications

• Auto-Coater is used in pharmaceutical industries for coating of tablets.
• In food industries candies are coated with sugar using auto coater.
• Various types of coating are possible like film coating with an organic solvent, enteric coating, and aqueous coating.
• Film coating to cover the unpleasant taste of tablets.

Parts

• Automated Control System
• Electric Motors
• Touch Screen Operation Panel
• Guide Plate
• Peristaltic Pump
• Spraying System
• Pan Cooling Surface
• Auto Coater
• Spray guns are the major parts of any auto coaters that are used in the industry

Installation of Auto coater

• The auto coater is placed in the allocated location in the process area.
• Power connections for the functioning of the equipment are done.
• Connections for air inlet and outlet are made.
• The liquid to be coated is filled in the liquid container and then the machine is turned on.
• The rotational speed of the machine is adjusted.
• The working temperature and pressure of the process are maintained and controlled externally as per the requirements.

Advantages of Auto-Coater

• Clean and automated coating system which prevents and dust entry into the coating zone.
• The production rate is very high due to the high degree of automation.
• Reduced weight of the final product because of thinner film coating compared to other coating types.
• Allows easier consumption of product due to film coating. o Flexible batch operations are possible.
• The film coating increases the effective period of the drug.

Features

• User-friendly control and operation by modern control systems.
• High atomizing and flexible spray guns for the coating process.
• Spraying is done from different angles as per requirement.
• High tech control systems to regulate the temperature and pressure conditions within the coating zone.
• Viewport for visual observation of coating process.
• The perforated pan has larger openings for a high-quality coating finish.
• Dust collection system for exhaust air having scrubber, exhaust blower, and filter.
• Some auto coaters have a rotating perforated drum for moving the particles while the coating is done.

Safety Features

• The auto coater has Overload pressure release mechanism.
• The auto coater has Emergency stop button.
• The auto coater has Separate production and technical areas.
• The auto coater has Perforated pan designed to prevent breaking up of tablets during rotation.

Specifications

Pan Diameter,  Approximate Working Capacity, Pan Mouth Diameter, Pan Speed,  Main Drive Motor, Inlet Air Blower Motor, Inlet air, Steam Consumption,

Compressed Air is the important parameter considered for the construction of any auto coater.

The working capacity of the auto coater ranges from 30 kg per batch to 500 kg  per batch.

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