Good tablet design is extremely important; it has an impact upon anticounterfeiting, tooling strength, tablet coating, durability and functionality. It also helps to avoid downstream manufacturing problems such as tablet sticking, picking, lamination, capping and premature tooling failures. It is essential to consider these at the beginning of the process to ensure a problem-free, high quality end product.
Several elements need to be considered when designing a tablet; here some of the most important ones are considered:
1. Tablet shape and profile
The first thing to consider is the tablet shape and optimum profile. There are two basic tablet shapes: round and non-round; however, the complexity of non-round shapes can vary and may require specialised tool manufacturing capability.
Once the base shape has been decided, tablet size must be determined; here consideration should be given to the type of press available for tablet manufacture, as this can limit the size of the tablet.
Next follows selection of the tablet. The type of profile required is influenced by several factors; the granule, embossing requirements, coating process, packaging and company branding. Thought should also be given to the volume of the tablet and whether it will be coated. Successful coating is dependent on tablet profile. Coated tablets, whether film- or sugar-coated, present challenges for the tablet designer. The complexity of the coating process is vast. Many of the variables are within the manufacturer’s control but expert tablet design can help eliminate potential problems.
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