Common Tablet Manufacturing Defects in Pharma | Part-2


Uneven distribution of color or pigmentation on the tablet surface.

Causes of Mottling:

  •  Colorants are not thoroughly blended ( mixed ).
  •  Chemical interactions between components can cause color variations.
  •  Insufficient drying.


Remedies for Mottling:

  • Use appropriate blending techniques.
  • Compatibility of colorants with other ingredients.
  • Perform proper drying.


It presents as a thin, unwanted edge around the perimeter of a tablet.

Causes of Flashing:

  • Excess amount of tablet material in the die cavity.
  • The powder fails to uniformly occupy the entire die cavity.
  • Upper and lower punches are misaligned.

Remedies for Flashing:

  • Use reliable feeding systems.
  • Proper alignment of punchs.


Breakage of tablet edges, resulting in small chips or fragments.

Causes of Chipping:

  •  Lack sufficient hardness.
  • Tablets with high friability tend to chip.
  • Tablets with sharp edges or corners.
  • Inadequate lubrication between powder and punches.


Remedies for Chipping"

  • Optimize the compression force.
  • Round the edges and corners.
  • Adequate lubrication between powder and punches.


Visible cracks or fissures on the tablet surface.

Causes of Cracking:

  • Excessive compression force.
  • Binder isn't good for sufficient strength.
  • Powder isn't lubricated.

Remedies for Cracking:

  •  Adjust the compression force.
  • Optimize the concentration and type of binder.
  • Appropriate lubricant is used.

Double Impression

Presence of two or more imprints on a single tablet.

Causes of Double Impression:

  •  Punches are not properly aligned.
  • Rotation of lower punches is not controlled.

Remedies for Double Impression:

  • Punches should be aligned.
  • Ensure correct assembly and positioning of the punches.

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