Common Tbalet Manufacturing Defects in Pharma | Part-1


1. Capping

Partial or complete separation of a tablet's crown or upper portion from the main body.

Causes of Capping:

  • Insufficient compression force
  • Lack good binding properties
  • Poor granules flow

Remedies for Capping:

  • Adjust the compression force.
  • Incorporate suitable binder.
  • Improve granules flow.


2. Lamination

Tablets split into layers or laminates.

Causes of Lamination:

  • Air entrapment.
  • Insufficient compaction force.

Remedies for Lamination:

  • Adjust pre-compression force to remove air from the granules.
  • Proper compression force.


3. Sticking

It happens when the tablet material adheres to the punches and dies instead of being ejected smoothly.

Causes of Sticking:

  • Improper lubrication.
  • Exist of hygroscopic or sticky ingredients.
  • Rough surface of Punchs/Die.
  • Inadequate dwell time.
  • Worn-out tooling.

Remedies for Sticking:

  • Select a suitable lubricant.
  • Adding suitable excipients (no hygroscopic ingredients).
  • Clean & replace rough tools.
  • Optimize dwell time.
  • Replace the worn-out tooling.


4. Picking

Specific type of sticking. It occurs when the tablet material is left behind on the punch faces with embossing designs.

Causes of Picking:

  • The same of Sticking.

Remedies for Picking:

  • The same of Sticking.


5. Binding

Undesirable adhesion of granules to the surface of the dies during the compression.

  • Causes of Binding:
  • Improper lubrication between granules & tools.
  • Excessive moisture.
  • Hygroscopic excipients.


Remedies for Binding:

  • Apply proper lubricants.
  • Monitor the moisture content.
  • Use non-hygroscopic excipients.

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