COATING TECHNOLOGY:

PROCESS,EQUIPMENT,PARTICLE
COATING, APPLICATION
TECHNIQUE, PROBLEMS
ENCOUNTERED
NAME: DISHA JOSHI
EN NO: 232070824003
M.PHARM 2nd SEM
GUIDED BY: DR. SAPNA.M.RATHOD

A.P.M.C. COLLEGE OF PHARMACEUTICAL

EDUCATION AND RESEARCH,HIMATNAGAR
TABLE OF CONTENTS

INRODUCTION
COATING
PARTICLE COATING
TYPES OF COATING
TYPES OF EQUIPMENT
APPLICATION TECHNIQUES
FLUIDIZED BED COATING
PROCESS
PROBLEM ENCOUNTERED
INTRODUCTION

 In the ancient time, Rhazes used psyllium seeds mucilage to

unmask the taste of pills.
 In 1838, Garot introduced the coating of pills by using
gelatin.
 In 1842, the first sugar-coated (SC) pill was imported from
France to the United States (US).
 In 1856, a Pharmacist in Philadelphia indigenously
manufactured coated pills.
 The tablet is one of the most popular and extensively used
solid dosage forms. Tablets are the compressed dosage form
that may or may not contains the active ingredient.
WHY DO WE NEED TO COAT THE TABLET?

 To mask the bitter taste

 Controls the drug
release
 To release the drug at
specific site
 For enhancing the
appearance by
 Ex: printing on the
tablets , attractive
colors
COATING

 The coating is defined as:

 A procedure in which the desired dosage form may
be a
 granule or tablet coated with an outer dry film to
obtain specific objectives such as
 masking taste or protecting against environmental
conditions.
BENEFITS

Prevents (tablets) from

stinking together

Mask disagreeable colors /

Provide mechanical strength
odor of tablets

API release can be

Companies could print their
controlled by coating
symbols, marks on tablets
• It could be site specific

The drug release rate in the

(GIT) could be controlled Mask taste and more stability
by controlling the achieve by coating
dissolution rate
 CORE
 The structure to which the coating is applied is called the
core or substrate.
 The core types may be crystals, various types of granules,
micro-pellets, tablets, hard gelatin capsules, and soft gelatin
capsules.
 The features expected from the core and the points to note
are:
• If the tablets adhesion of the coating layer requires that the
core surfaces are smooth and do not contain dust.
• Tablets are used as a core, they must be convex to prevent
them from sticking.
• The core should be resistant to rotation, friction, impact
during coating and should be of appropriate hardness.
PARTICLE COATING
 CONTINUE…

 Particle coating to alter the surface properties and/or functionality of fine

particles or powders.
 Powder material designed to have specific properties are called Engineered
or Designed Particulates. Basically there are three types of particles.

o Coated particles (discrete and film coatings),

o Designer particles having a specific size, shape or morphology and
o Composite particles (nano granulated particles)
 Types of particle coating: There are basically two types of Particle coating
finds Pharmaceutical Applications.
o Wet Particle Coating
o Dry Particle Coating
 TYPES OF PARTICLE COATING
 1. WET COATING TYPES OF IT:
 Generally, a mixture of polymers, pigments
and excipients is dissolved in • Coacervation–
 an appropriate organic solvent (for water Phase
insoluble polymers) or water (water soluble separation
polymers)
process
 to form a solution, or dispersed in water to
• Aqueous-phase
form dispersion, and sprayed onto the dosage
forms separation,
 and dried by continuously providing heat until coacervation
a dry and smooth film coating film is formed. • Nonaqueous-
 A typical liquid coating process is carried out phase
in a rotary pan coater for larger size solid separation
dosages such as tablets, • Fluidized bed
 or in a fluidized bed coater for smaller size coating
dosage forms such as pellets, pills, granules
etc. Wet particle coating techniques .
COACERVATION– PHASE SEPARATION
PROCESS

(a) Core material dispersion

in solution of shell
polymer;
(b) Separation of
coacervate from
solution;
(c) Coating of core material
by microdroplets of
coacervate;
(d) Coalescence of
coacervate to form
Microcapsules
 Aqueous-phase separation
• The complex coacervation is principally a pH dependent
process.
• Above a certain critical pH value, the system depending upon
• its acidic or basic nature may produce microcapsules. Below
that pH value they will not form.
 2.Dry coating:
 Dry particle coating involves
mechanically fixing fine particles (guests) TYPES OF IT:
onto the surface of relatively larger
particles (hosts). 1. Hot melt coating
 Materials with relatively large particle 2. Supercritical fluid
size (1–200 μm) form a core and
coating
 these core (host) particles are
3. Vapor coating of
mechanically coated with fine submicron
(guest) particles; powders
 no liquid of any kind (solvents, binders 4. Electrostatic
or water) is required. fluidized bed
 Compared to solvent and water based coating
coating, the dry coating method is 5. Particle coating
favorable regarding environmental via atomic layer
friendliness, safety and cost. deposition
 It might be a very suitable coating method
in order to coat foods and drugs which are
sensitive to organic solvents or water.
 Supercritical fluid  Hot melt coating:
coating: • As its name implies, is
• The coating agent is applied in its molten state
solubilized in supercritical over the substrate and then
carbon dioxide in a high solidified upon cooling.
pressure vessel. The active • Partially hydrogenated palm
ingredients are dispersed in oil (58–63°C) and
the supercritical solution. cottonseed oil (61–65°C)
• Coating materials were • Beeswax (62–65°C),
mainly lipids, (e.g., • paraffin wax (55°C),
mono-di-and tri- • carnauba wax (84°C)
glycerides of various • Polyethylene glycol 3350
fatty acids), fatty (54–58°C)
alcohols
TYPES OF
COATING
TYPES OF COATING

Types of coating :

Sugar coating COMPRESSED COATING

DIP COATING
Film coating
VACCUM COATING
Enteric coating
ELECTROSTATIC COATING

Specialized coating
 SUGAR COATING:

Sugar coating is done by rolling the tablets in

heavy syrup, in a similar process to candy making.

It is done to give tablets an attractive appearance and

to make pill-taking less unpleasant.

However the process is tedious and time-consuming

and it requires the expertise of highly skilled
technician.

It also adds a substantial amount of weight to the

tablet which can create some problems in
packaging and distribution.
 Sugar coating…….

The basic sugar coating involves the following steps:

 Sealing,
 Sub-coating,
 Syruping (smoothing),
 Polishing.
 Printing
 Material used in sugar coating:
Seal coating Syrup-coating Sub-coating Polishing

Zein / shellac Colorant Gelatine Carnauba wax

(yellow)
Oleic acid Sub coating Acacia Bees wax
powder (white)
Propylene glycol Calcium Sugar cane Paraffin wax
carbonate powder

PEG Cane sugar Corn syrup Naphtha

powder

Alcohol Syrup Corn starch

Methylene Distilled water Syrup

chloride Distilled water
 FILM COATING
 Film coating is a process that involves the deposition of a thin, but uniform,
film on to the surface of the substrate.
 Film coating is a very flexible process that allows a broad range of products
(e.g. tablets, powders, granules, non-pareils, capsules) to be coated.

 The characteristics of film coating:

 Solubility required for the intended use, e.g., free water solubility, slow
water solubility, or pH-dependent solubility(enteric coating)
 Stability in the presence of heat, light air, and the substrate being
coated. The film properties should not change with aging.
 Essentially no color, taste or odor.
 Compatibility with common coating solution additives.
 Non-toxicity with no pharmacological activity, and ease of application to
the particles or tablets.
 Ease on printing procedure on high-speed equipment.
 • Polymers (ex: HPMC,CMC, PVA,
PVP, Sod. Alginate, PEG etc. either
alone or in combination
• Solvent (ex: Water, Ethanol, Methanol,
Isopropanol, Chloroform, Acetone,
Methyl ethyl-ketone, ethyl chloride.)
• Plasticizers (ex: Phthalate esters,
Material phosphate esters, other esters like
citrates, stearates, oleate, oils, glycerol,
used in glycols etc.)
film • Additives Pigments
coating: • Opacifier
• Anti-tacking ( ex: Talc)
• Film adhesion enhancer
• Sweeteners
• Flavors
• Anti foaming agent
• Colorants
ENTERIC COATING
 Enteric coating: This technique is used to protect
the tablet from disintegration in the acid
 environment of the stomach for one or more of the
following reasons:
 i) Prevention of acid attack on active constituents
unstable at low pH,
 ii) To protect the stomach from the irritant effect of
certain drugs,
 iii) To facilitate absorption of a drug that is
preferentially absorbed distal to the stomach
EXAMPLES OF COATED TABLETS

Sugar coating Film coting Enteric coating

Tylenol Advil (Ibuprofen) Nexium
(Acetaminophen) 200mg (Esomeprazole)
325mg 20mg
Motrin (Ibuprofen) Lipitor Aciphex
200mg (Atorvastatin) (Rabeprazole)
10mg 20mg
Benadryl Crestor Prilosec
(Diphenhydramine) (Rosuvastatin) (Omeprazole)
25mg 10mg 20mg
Zantac (Ranitidine) Plavix Duexis
75mg (Clopidogrel) 75mg (Ibuprofen/Famotid
ine) 800mg/26.6mg
 Vacuum Film coating  Compression coating
• A revolutionary process • A relatively uncommon
utilizing a specially designed technique with specific
battled pan. advantages.
• The pan, which is hot and • Useful when the tablet
water-resistant, can be sealed to core cannot tolerate
create a vacuum. organic solvents or water,
• Tablets are placed in the pan, but coating is necessary for
and nitrogen displaces the air taste masking or enteric
until the desired vacuum level is qualities.
achieved. • Requires a specialized
• Coating solution is applied tablet machine.
using an airless spray technique.
• A vacuum system extracts the
vapors of evaporated liquids.
• Organic solvents can be
effectively employed, making it
environmentally friendly
TYPES OF EQUIPMENT

2. Gas 3. Vacuum Film

1. Pan coating
Suspension Coating

Conventional
Fluidized Bed 4. Dip Coating
coating pan

Spray
Perforated 5. Electrostatic
Congealing/Dryi
Coating Pans Coating
ng

Multi-Drum Lab
6. Compression
Perforated Pan
Coating
Coater
PAN COATING

 Tablet coating pan is used for

sugar and film coating of
tablets, pallets, granules etc.
 It consists of ellipsoidal
shaped pan made of stainless
steel sheet and mounted on
the gear box shaft which is
driven by an electric motor.
 After the tablets are loaded,
the pan starts to rotate, driven
by an electric motor. The
rotation enables the tablets to
tumble and get coated with Pan coating machine
the premixed solution.
PERFORATED PAN

 This device is designed with

either a partially or fully
perforated drum.
 The drum works to coat
tablets by spinning on a
horizontal axis in an
enclosed housing.
 The perforated pan uses
spraying nozzles to evenly
apply coating solution to the
surface of the rotating tablet
bed.
 APPLICATION TECHNIQUES/METHODS
Non spray techniques Spray Techniques Electrostatics
Dip Coating Conventional Air Electrostatic spray
Atomization

Flow coating Airless Atomization Rotary Atomization

Dip-Spin Coating Air-Assisted Airless

Atomization

Roll Coating (Direct High Volume, Low

and reverse) Pressure Air-
Atomizing Spray

Flame Spray Coating

Fluidized Bed
NON SPRAY TECHNIQUES

Dip coating  Flow Coating

• Dip coating refers to • In flow coating, the part
immersing a piece into a tank
containing
is suspended, and the
coating is poured over it.
• the coating material, removing
the piece from the tank, and • The excess material drips
allowing it to drain. off and is collected for
• The coated piece can then be reuse.
dried by force-drying or • In a flow-coat system, 10
baking.
to 80 separate streams of
• Dipping is extremely
dependent on coating material are
• the viscosity of the paint, is
directed to impinge on
very messy, and may be the parts.
highly hazardous.
ELECTROSTATIC TECHNIQUE

Electrostatic Spray
 In electrostatic coating, the fluid is atomized, and then
negatively charged.
 The part to be coated is electrically neutral, making the
part positive with respect to the negative coating droplets.
 The coating particles are attracted to the surface and held
there by the charge differential until cured.
 With an electrostatic spray gun, the droplets pick up the
charge from an electrically charged electrode at the tip of
the gun.
 The charged particles are given their initial momentum
from the fluid pressure/air pressure combination.
 Electrostatic spraying offers high transfer efficiency (65
% to 95 %) and excellent edge coverage.

Electrostatic Spray technique

SPRAY TECHNIQUE

Conventional Air
Atomization
• In conventional or air • Compressed air from the
atomized spraying, the center of the nozzle
coating is supplied surrounds the fluid with a
• to a spray gun by siphon,
hollow cone as
gravity, or pressure feed. • it leaves the nozzle,
• When the gun trigger is
breaking the coating into
small droplets and
pulled, the coating flows
transferring velocity to it.
through the nozzle as a fluid
stream.
FLUIDIZED BED COATING
 The latest technology called
fluid bed processing helps in  When the particles are
 attaining the coating, drying reaching to the top of the
and granulation of a product equipment, they tend to
so that uniform drying and gravitational pull and so
coating takes place. fall down and the process

is suspending continues.
Fluidization is when a gas is
 This process is called as
sent through a nozzle with a
velocity of greater fluidization of suspended

particles.
than the settling velocity of
particles or solids, the
particles tend to suspend in
the air provided and continue
in the stream of upward gas.
FLUIDIZED BED PROCESSING

Fluidized bed coating

 PROCESS
 Air suspension of particles in the coating chamber (particles
dynamics).
 Spraying of coating material as droplets with the objective to
increase the probability of particle-droplet
 impacts but droplets can easily be dried (heat transfer) before
the collision with the particle. In this case there is no coating.
 Spreading of droplets on the particle surface followed by
flattening and adhesion of the droplet on the particle (mass
transfer).
 Then, in the best case, coalescence of droplets occurs on the
particle surface before drying (heat transfer) of the droplets to
form a layer.
 Layering or superposition of different layers of drop-lets
around the particle resulting in a homogeneous reservoir
system, i.e. a real coating.
 After several cycles of wetting-drying, a continuous film
will be formed, with a controlled thickness and a
composition depending on the materials used.
 It is mainly at this stage that the tendency for
agglomeration between two or several particles is high.
 The success of the coating operation depends on the
spreading of the droplet on the particle surface after
collision.
a) top spray; (b) bottom spray; (c) Wurster; (d) tangential or
side rotor spray.
SPRAY TECHNIQUES

Top spray process: Top-spraying is the most well known

process for wet granulation, and it has been used in various
industries like pharmaceutical, food, detergent, and fertilizer
industries for more than 30 years. A top-spray processor has
three components

  An exhaust system (including the processor's filter

housing).

 An air-handling system, which can be equipped with de-

humidification or humidification and dewpoint control.

 A expansion chamber and product container

Top spray Bottom-spray Tangential spray
 Bottom-spray coating:
• Provides a highly organized
 In the container, there is
particle flow & high quality
reproducible film so a second cylinder
(coating partition),
• this system is used
which is raised slightly
extensively for sustained
release/ controlled release/ above the perforated
extended release and plate. Centrally, in the
delayed/ enteric coating plate below this
 partition, there is a
This process employs a
cylindrical product container
nozzle used to dispense
with perforated plates. the coating solution.
Tangential spray process: • This technique permits
the production of pellets
• The physical technique with high dose loading of
and processing principles activities in relatively
are quite similar to short time.
bottom spray process, • Tangential spraying can
• only that the production be used to produce
motion is provided by a • pellets or granules that
motor driven rotor disc. require successive
• The spraying nozzles are coating for modified
located tangentially in the release and controlled
chamber. release.
PROBLEMS ENCOUNTERED
Tablet defects illustrative image Remedies

Sticking and o A reduction in the

Picking: Over liquid application
wetting or excessive rate or increases in
film tackiness the drying air
causes tablets to temperature
stick to each other

Orange-Peel o This indicates that

Effects : spreading is
Inadequate impeded by too
spreading of the rapid drying or by
coating solution high solution
before drying viscosity thinning
causes a bumpy or the solution with
"orange-peel" additional solvent
Tablet defects illustrative image Remedies

Bridging and o Increasing the

Filling: plasticizer
During drying, the content or
film may shrink and changing the
pull away from the plasticizer
sharp corners
Filling is caused by o Monitoring of the
applying too much fluid application
solution rate
Color Variation: A reformulation
This problem can be with different
caused by plasticizers and
processing additives is the best
conditions or the way to solve film
formulation. instabilities
Tablet defects illustrative Remedies
image

Cracking: o Internal stresses

Cracking occurs if in the film can be
internal stresses in minimized by
the film exceed the adjusting the
tensile strength of the plasticizer type
film and
concentration
Hazing/Dull Film: o The solution is
This is sometimes that to maintain
called bloom. It can temperature
occur when too high
a processing
temperature is used
for a particular
formulation
Tablet defects Illustrative image Remedies

Blistering: o Use mild

It’s a coating drying
defect which methods
occurs when film
separates from the
core / substrate
and form blister
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