Evaluation of recent advances in continuous film coating processes

Area of Science:

• Pharmaceutical Manufacturing
• Coating Technology
• Process Engineering

Background:

• Continuous film coating processes offer high production rates but face challenges in pharmaceutical adoption due to perceived product losses.
• Recent advancements in continuous coater designs aim to improve coating uniformity and minimize product loss during pharmaceutical production.
• This study evaluates newly redesigned continuous coating pans from two manufacturers.

Purpose of the Study:

• To evaluate recent improvements in continuous coater designs.
• To assess coating uniformity in continuous film coating processes.
• To determine the reduction in product losses during continuous coating operations.

Main Methods:

• Multivitamin tablets were coated with Opadry((R)) II in batch and continuous modes.
• Tablet color development and uniformity were assessed.
• Soft gelatin capsules were coated with Nutrateric((R)) delayed-release coating.
• Capsule resistance to simulated gastric fluid was measured to evaluate coating performance.

Main Results:

• Continuous coating processes demonstrated significant improvements in coating uniformity for both immediate and delayed-release formulations.
• Product losses were substantially reduced in continuous coating operations compared to traditional methods.
• Both immediate-release and delayed-release case studies confirmed the efficacy of the improved continuous coating systems.

Conclusions:

• Continuous film coating processes are now capable of achieving high-quality aqueous film coatings.
• Recent advancements have successfully addressed concerns regarding product loss and coating uniformity.
• Continuous coating technology presents a viable and efficient option for pharmaceutical production.