Making tablets might look simple from the outside — press a button, and they pop out perfectly shaped, right? But anyone who’s worked in pharmaceutical manufacturing knows the truth: there’s a lot that can go wrong between formulation and the final product.
From tablets that split like sandwich layers to ones that stick to the punch like bubble gum, every production team has faced these frustrating problems. The good news? Most of these issues have clear causes and even better solutions.
Here’s a breakdown of the most common tablet defects, why they happen, and what you can do to prevent them.
Sources of Tablet Defects in Pharmaceutical Chemistry
Tablet defects can come from both formulation problems and process-related issues. The sources are-
- Moisture
- Improper drying
- High-speed machines
- Tools setting problem
- Excess use of binders
- Lack of proper lubricant selection
- Air interaction
- Lack of knowledge
- Improper training
- The abnormal ratio of excipients
- Temperature adjustment
Even small slip-ups here can snowball into bigger problems during compression
The Tablet Troubles You’ll Probably Run Into
1. Binding
Let’s start with a classic. Binding happens when granules stick to the die wall during compression. When that tablet is released, the edges appear rough, sometimes with deep, scratch-like marks.
Why it happens: Usually because the lubrication isn’t enough, or it’s not spread evenly throughout the mix.
How to fix it:
- Add more lubricant (but not too much)
- Make sure it’s mixed in evenly
- Adjust granule moisture — sometimes just a little more helps
2. Sticking, Picking, and Filming
These three often get lumped together because they all involve material clinging to the punch faces.
- Sticking is when the entire surface of the tablet sticks to the punch.
- Picking is a little sneakier — just a small patch of the tablet tears off and sticks.
- Filming is a slower build-up over time, creating a thin film on the punch.
Main causes: Too much moisture, poor drying, or sometimes just the punch design itself.
Your move:
- Improve drying before compression
- Recheck your granule moisture range
- Try anti-stick coatings or polish on punches
3. Capping and Lamination
These are the ones that make your stomach drop when you spot them.
- Capping is when the top layer of the tablet pops off like a lid.
- Lamination is more like slicing — the tablet splits into horizontal layers.
What causes it: Trapped air in the granules is usually to blame. During compression, air gets squeezed in, and when pressure is released, the tablet expands and starts splitting.
Fixes:
- Slightly increase granule moisture
- Add dry binders (like PVP or gum acacia)
- Adjust punch/die fit — too tight can make things worse
- Try slowing down the press to give air time to escape
4. Mottling
Ever seen a tablet with blotchy colors or weird light/dark patches? That’s mottling — and it’s not a great look, especially for patient confidence.
Likely reasons:
- Dye wasn’t mixed evenly
- Some ingredients degrade and change color
- Drying too fast causes color migration
- Ingredient particle sizes vary too much
What helps:
- Use colorants that stay put
- Reduce drying temps
- Blend thoroughly and consistently
- Consider adjusting the solvent or binder system
5. Weight and Hardness Problems
These may not be as visible, but they matter just as much, especially for dosage accuracy.
Why does it happen?
- Poor flowability of granules
- Uneven feed in the hopper
- Fill depth inconsistencies
What to do:
- Improve granule flow (sometimes a little colloidal silica helps)
- Check and re-check your equipment settings
- Keep an eye on press consistency over long runs
Disclaimer
This article is for educational purposes only and is not intended as manufacturing or regulatory advice. Always follow your site’s SOPs and comply with cGMP guidelines.
Want More?
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Read more:
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