Coating Technology

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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 m.

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 Vacuums 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 - 5000. 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.

OHara 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

OHara 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

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