Introduction

One of the biggest problems that our customers contact us about is

soft crumbly tablets. We know how annoying it can be when you
have a customer to keep happy and every tablet is coming out way
below acceptable.

So we have put together a short list of the main problems that can
cause or fix these frustrating moments.
Tip 1 | Sieve
Create Consistent Particle Size
It is really important to make sure that your mix is consistent. This
does two things. Firstly it stops clumps of powder blocking up the
flow of the mix through the machine. Secondly it makes sure that
every tablet is even and that is has the right amount of active in it.
So the best way to get a consistent particle size is to put the entire
mix through a sieve before mixing it for the final time. If you are
doing small mixes this can be done with a hand sieve. If you need
to do lots of mixes then we are also able to provide industrial
sieves.
Tip 2 | Binders
Make Sure You Have Enough in your mix

Unless you active is a DC (Directly Compressible) then you will

need to use binders. We recommend not using less than a 2:1 ratio
of binders to actives. In the case of a 100mg caffeine tablet you
would have minimum 200mg of binders to the 100mg of caffeine.
A really good tool is our tablet mix calculator which does all the
maths for you and works how much binder you need to use.
Tip 3 | Check Flow
Look at the dies / fill trays
Next problem is the powders flowing. Even if you have sived it and
got a 2:1 ratio some actives can really mess up the flow of a mix.
This means that the dies will not be filling evenly on every press. So
some of the tablets could be 200mg the next could be 250mg and
the next 150mg. You can tune the press by hand to exactly 200mg
but it will be jumping all over the place.
To check for this on the TDP range, turn off the press and remove
the boot while there is still powder in it. If it does not all instantly fall
out this is your problem.
To check for this on the RTP range look at the fill tray. Is there
powder in every section. Is there a little extra coming out of the
overflow and circulating background to the start?
The best way to fix this is to add anti-caking agents and dry
lubricants. LFA has both in our excipients rage for more information
or help with this contact our team.
Tip 4 | Adjust Pressure
Make sure you are hitting it hard enough

The next thing to do is check that you are hitting it with enough
pressure. You want the press to be just before the point where
it would jam. The best way to work out this point on a TDP 5 is to
slowly increase the pressure until it can not be turned over by hand.
Then turn the pressure back by 1⁄4 to 1⁄2 trun.

On the RTP’s the best way to work out this point is while the
machine is running increase the punch pressure until the machine
makes a tapping like a hammer on a metal surface. Some of the
more advanced RTP’s have digital readouts showing you the
current pressure being exerted.

We have a video explaining how to fix this here

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Tip 5 | Check Binding Agents
Press With Firmapress
So this is really all about fault finding. A lot of the time we have
customers call up and say “Our press is not working, it has to be a
problem with the machine.” They then drive 3 hours to get to us for
us to put Firmapress in it and show them that the press is fine.

So the best thing to do is take a 200g of Firmapress and add

it to your machine without any API’s (actives). If you are able to tune
your press and make a hard shiny tablet then the problem lies with
your mix and more specificity the active ingredient.

If you are not able to make a good tablet with just the mix then the
problem is with the press. Give our team a call or an email and we
will help you work out what is going on.

Tip 6 | Granulate or Use a

Bigger Die
Finally, If you have tried everything else and you still are not getting
the hard, smooth table that you want you will have to try one of two
things

a) Change your die for a bigger one and try to use more binder
and flowing agents. Or,

b) Granulation. Granulation is a complicated however it is

something that our team are able to help with.
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