Sticking and Picking in Pharmaceutical Tablet Compression: An IQ Consortium Review

Area of Science:

• Pharmaceutical Manufacturing
• Materials Science in Drug Delivery

Background:

• Tablet sticking and picking are significant challenges in pharmaceutical manufacturing, leading to defects, production downtime, and yield loss.
• This issue can unpredictably emerge at any development stage or during process transfers between manufacturing sites, which are increasingly common.
• Sticking is a complex, multifactorial problem where isolated solutions may fail or worsen other issues.

Purpose of the Study:

• To review current research and practical strategies for mitigating and resolving tablet sticking and picking.
• To highlight common causes and effective solutions for this persistent manufacturing defect.
• To explore potential future research directions in tablet manufacturing.

Main Methods:

• Review of current literature and industry practices related to tablet sticking.
• Analysis of multifactorial causes involving the active pharmaceutical ingredient (API), formulation, tablet tooling, and manufacturing process.
• Structured approach to identifying and implementing remedies for sticking and picking issues.

Main Results:

• A broad-based strategy encompassing API, formulation, tooling, and process is essential for a robust solution.
• Understanding the multifactorial nature of sticking is crucial for effective problem-solving.
• Structured investigation of causes and remedies is recommended for formulators.

Conclusions:

• Addressing tablet sticking requires a holistic approach rather than a single fix.
• Effective management of sticking and picking relies on a deep understanding of its complex, multifactorial origins.
• Continued research is needed to develop more predictable and reliable solutions for tablet manufacturing challenges.