Improvements in Coating technology
Submitted to : Dr.Dipankar Bhadra
Submitted by : Sakshi Taneja M.Pharm 2nd sem
Contents Definition Historical prespective Purpose of coating Types of coating
Types of coating techniques Coating equipments
Historical prespective Based on islamic literature (850-923) “rhazes”. Sugar coating (1837-1840) in copaiba.
Dr. “Dale Wurster”- 1950 – air suspension coater. Abbott laboratories – 1953. Accela cota, hi-coater,dria coater.
contd… Last 40 years Introduction of the sidevented tablet coating pans (with perforations) This evolution was required for the introduction of aqueous based film coating polymers to the pharma industry Carbon steel construction except for pan Many screws, not welded in places Not very GMP
Purpose of coating Easier to swallow. Masking taste and unpleasant smell. Reducing light sensitivity and atmospheric oxidation improving
stability. Core is inelegant. Colour migration from core. Reduced friction in packaging process. Modified drug release profile. Separate incompatible substances. http://www.cvg.ca/Presentations/2008/OHara%20Oct%209%2008%20presentation %20to%202008%20CVG%20convention%20R1.pdf
Types of coating
Film coating.
Sugar coating. Compression coating.
http://www.authorstream.com/Presentation/robin_vinnu-623384-tabletcoating/
Film coating Film coating is the process whereby a tablet, capsule,
or pellet is surrounded by a thin layer of polymeric material. A film coating is a thin polymer-based coat applied
to a solid dosage form such as a tablet. The thickness of such a coating is usually between 20-100 µm.
http://www.pformulate.com/pformcoating.htm http://formulation.vinensia.com/2011/05/film-coating-tablet-coatingprocess-and.html
Sugar coating Sugar coating is an effective
process for the application of thick coating layers, primarily for masking taste. The syrup is sprayed onto the particles. The introduction of the process air evaporates the fluid and dries the sugar coating. When the sugar coating solution is added discontinuously, the particles remain in the process until the required coating thickness is achieved.
http://www.cjtech.co.kr/Process%20Principles%20Sugar%20Coating.htm
Compression coating It involves the compaction of granular materials around a
preformed tablet core using specially designed tableting equipment. Compression coating is a dry process.
This type of tablet (compression coated tablet) has two parts,
internal core and surrounding coat. The core is small porous tablet and prepared on one turret. For preparing final tablet, a bigger die cavity in another turret is used in which first the coat material is filled to half and then core tablet is mechanically transferred, again the remaining space is filled with coat material and finally compression force is applied.
http://formulation.vinensia.com/2011/05/compression-coating-tablets.html
Coating Process Design & Control Tablet coating takes place in a controlled atmosphere inside a
perforated rotating drum. Angled baffles fitted into the drum and air flow inside the drum provide means of mixing the tablet bed. As a result, the tablets are lifted and turned from the sides into
the centre of the drum, exposing each tablet surface to an even amount of deposited/sprayed coating. The liquid spray coating is then dried onto the tablets by
heated air drawn through the tablet bed from an inlet fan.
diagram
Contd… The coating process is usually a batch driven task consisting of the following phases: Batch identification and Recipe selection (film or sugar coating) Loading/Dispensing (accurate dosing of all required raw materials) Warming Spraying (application and rolling are carried out simultaneously)
Drying Cooling Unloading
Types of coating techniques 1. Vaccum coating 2. Electrostatic coating.
3.Compression coating. 4. Magnetically induced coating.
Vaccum coating The product passes through the portion
of the coater known as the application chamber at a constant speed of up to 500' per minute. Paint is drawn from a reservoir by a
diaphragm pump, filtered for large particles, and delivered through a hole into the bottom of the coater head. The level of the coating then rises within the head until the part passing through is completely surrounded or immersed.
Contd… A vacuum is applied to the reservoir and the application
chamber. The reservoir is a sealed environment attached to the coating head. The coating head contains the only area for air to inrush and that is the space between the product and the template profile. It is this inrush of air that is used to strip excess coating from the product. This application and removal method stratifies the coating on removal and then it is drawn up and over a baffle and drains to the reservoir.
Electrostatic coating It is a manufacturing process
that employs charged particles to more efficiently paint a workpiece. Paint, in the form of either powdered particles or atomized liquid, is initially projected towards a conductive workpiece using normal spraying methods, and is then accelerated toward the workpiece by a powerful electrostatic charge.
Contd… The workpiece travels down a conveyor belt towards to a
paint booth, where it is sprayed with electrostatically charged paint particles. Integrated into the paint booth is a powder recovery unit,
which recovers between 95% and 100% of the paint overspray coatings. After the workpiece is coated, it continues on the
conveyor belt to an oven, where the paint is cured.
Compression coating It involves the compaction of granular
materials around a preformed tablet core using specially designed tableting equipment. Compression coating is a dry process. This type of tablet (compression coated
tablet) has two parts, internal core and surrounding coat. The core is small porous tablet and prepared on one turret. For preparing final tablet, a bigger die cavity in another turret is used in which first the coat material is filled to half and then core tablet is mechanically transferred, again the remaining space is filled with coat material and finally compression force is applied.
Magnetically induced coating Nickel zinc ferrite nanoparticles in the size range of 30–
40 nm have been prepared. Coated with polyelectrolyte, the particles were induced to assemble on glass substrates under strong magnetic fields from 0.25 to 0.5 T. The predominant orientation of the assembled chains was observed to be along the direction of the magnetic line of force. As the coating layers increased, ring morphology could be observed. The magnetic properties of the assembled structures were measured and compared to those of ferrite particles prepared without a magnetic field applied.
Oerlikon Leybold Vacuum’s magnetically levitated turbo molecular pump
Coating equipments Standard coating pan systems
Pellegrini pan Immersion sword system Immersion tube system Perforated pans systems Accela cota & Hi-coater system
Dria-coater Glatt coater
Fludized bed coater
PRECISION - Fluidized bed coater It is Bottom-spray fluid bed
coating . Precision coating of small particles such as powders, granules, crystals, pellets and small tablets The PRECISION COATER™(Patented) offers precise coating of particles from 50 - 5000µ. The coating liquid is sprayed up into to a fluidized bed which uses advanced fluid dynamics to control the flow and achieve a high degree of coating uniformity. Capacity: from 200g to several ton/batch http://www.niroinc.com/pharma_systems/fluid_bed_coating.asp
TOP SPRAY COATER Top-spray fluid bed coating is Cost-effective pellet
coating In the TOP SPRAY COATER™, particles to be coated are suspended in the fluidized bed, and the coating liquid is sprayed down on to them from above. Capacity: from 50g to several ton/batch
http://www.niroinc.com/pharma_systems/fluid_bed_coating.asp
Roto - Processor™ Wet granulation pelletization is Granulating and
spheronizing a powder mixture The active substance is mixed with 5-30% microcrystalling cellulose and the mixture granulated with water or an organic solvent. The granules are then compacted and spheronized. This operation can be performed using the Roto - Processor™ or Pellet - Processor™.
http://www.niroinc.com/pharma_systems/fluid_bed_coating.asp
GEA Niro Pharma Spray Dryer™ Spray drying coating is an efficient continuous
coating of fine powders The GEA Niro Pharma Spray Dryer™ is used to coat fine powders. The particles are suspended in a polymer solution, then spray dried. Capacity: up to several ton/hr
http://www.niroinc.com/pharma_systems/fluid_bed_coating.asp
Aeromatic-Fielder™ FlexStream™ FlexStream™ (Patent Pending) Fluid Bed - Granulation, Drying
and Coating in ONE process container It is a new Multi-Purpose
Processor from GEA Pharma Systems that uses proven fluid bed technology to achieve granulation, drying and pellet coating (or tablet coating) in ONE processor.
http://www.gea-ps.com/npsportal/cmsdoc.nsf/WebDoc/webb7h6p3k
Contd… Process Description
The FlexStream™ by Aeromatic-Fielder consists of a fluid bed product bowl with several two-fluid atomization nozzles to distribute the granulation or coating liquid directly into the fluidized powder or pellet layer. A third low-pressure air stream comes directly from the fluid bed inlet plenum to create a particle-free area around the spray pattern of each nozzle. Using low pressure results in much better control of the granulation and coating processes with less fines, less agglomeration when coating pellets resulting in a significantly improved yield .
http://www.gea-ps.com/npsportal/cmsdoc.nsf/WebDoc/webb7h6p3k
Thomas engineering The coating process proposed by Thomas
Engineering has been used for coating large volume OTC products such as ibuprofen and neutraceuticals. The pan employs a different kind of baffle arrangement compared with the vector equipment and the angle of the pan is not adjustable.
O’Hara Technologies
This is the most recently introduced coating
equipment and shows certain processing features in common with the above two coaters, especially with regard to the design of integral baffles .
The coating process is divided into four air zones and
six coating zones, which facilitate initial tablet warming, coating application and final drying. http://www.iptonline.com/articles/public/pg70nonprint.pdf
O’Hara Technologies
Cimbria Continuous coater Continuous Coaters are used for application of
protective chemicals like insecticides, pesticides and fungicides to seed in a continuous process. With their patented atomizing nozzle, they are
ideally suited for the liquid treatment and the incrustation of all seed varieties. Even fragile seeds, such as maize and pulses, are treated with care during the admixture in the rotating mixing drum. http://www.cimbria.com/en-GB/Home/Solutions/SeedProcessing/ProductDetails.aspx?GroupID=GROUP113
Contd… The continuous seed treater has been designed in
self-supporting all-steel construction. All metal parts in direct contact with the treating agents (such as mixing drum, atomizing nozzle etc.) are made of rustproof material. The mixing drum is driven by a geared motor via V-Belt. All drive motors, pump and switching functions are permanently wired inside the integrated switch cabinet.
http://www.cimbria.com/en-GB/Home/Solutions/SeedProcessing/ProductDetails.aspx?GroupID=GROUP113
Cimbria Continuous coater
Thank you
