n Plant Training Report of Incepta Pharmaceuticals.The topic was Current Technologies for Solid Dosage Manufacturing.

1. IN PLANT TRAINING REPORT OF INCEPTA PHARMACEUTICALS LIMITED.
Submitted by
Mehedi Shah
ID: 161328
Esrat Jahan
ID: 161316
Session: 2015-16
Dept. of Pharmacy,
Pabna university of science and technology.
Topic: Current Technologies for Solid Dosage Manufacturing

2. 2
Contents
Topic
No.
Topic Name Page No.
01 Solid Dosage form 03
02 Modern manufacturing trends for solid dosage form 04-05
03 Current technologies for solid dosage manufacturing
➢ For Granulation
➢ For Blending
➢ For Milling
➢ For Coating
➢ For Powder
➢ For Compression
➢ For Capsule
➢ For Blister Packaging
➢ For Strip packaging
06-18
04 Conclusion 19

3. 3
Solid dosage forms
The solid dosage forms, which are solid in nature contains one or more drugs for
therapeutic effects and excipients like Binders, Sweeteners, coloring agents, etc.
Example: Tablets, capsules, granules, sachets, powders, dry powder inhalers, and
chewable tablets.
Advantages of solid dosage form:
• More stable than other dosage forms.
• Easy to handle.
• More accurate of the dosage form.
• No preservation required.
Disadvantages of solid dosage form:
• Expensive Machines.
• Tough to swallow for kids and patients in sleeping
condition.
Types of solid dosage form:
We can divide solid dosage form into 2 parts according to the amount of the dose-
1. Unit Dose
• Tablets
• Capsules
• Granules
• Sachets
• Lozenges
• Pills
• Dry powder inhaler
• Chewable tablets
2. Bulk Dose
• Powder (External and Internal)

4. 4
Modern manufacturing trends for solid dosage forms:
Continuous processing for solid dosage manufacturing is a rapidly growing concept. The
advancement in the processing equipment such as the oscillating granulators, strip packing
machines, blister packaging machinery, liquid filling machinery, liquid manufacturing plants and
many more has made continuous manufacturing a current reality. This method of processing is
most preferred because it has a low residence time, variables can be changed and the results can
be explored rather quickly. The implementation of continuous manufacturing as opposed to batch
processing is now much easier and cost effective.
Figure: Continuous manufacturing equipment (Syntegon)
Orodispersible tablets are gaining importance among novel oral drug-delivery system as they
have improved patient compliance and have some additional advantages compared to other oral
formulation. They are also solid unit dosage forms, which disintegrate in the mouth within a minute
in the presence of saliva due to super disintegrants in the formulation. Thus, this type of drug
delivery helps a proper peroral administration in pediatric and geriatric population where
swallowing is a matter of trouble.

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Figure: Orodispersible tablet
Current technologies for solid dosage manufacturing:
For Granulation: Granulation is the process of forming grains or granules from a powdery or
solid substance, producing a granular material.
Oscillating granulator is used for gentle homogenization, size reduction, grading and sieving
of dry, sensitive powders and granules in pharmaceutical, chemical and food industries. Oscillating
Granulator has one rotor with five edges, which oscillate on horizontal axis at about 180 per
minutes.
Rapid mixer granulator is widely used equipment in pharmaceutical manufacturing. It
is used to mix the pharmaceutical ingredients and make the granules before compression and also
called a high shear mixer.
Fluidized bed dryer (also called fluid bed dryer) is a kind of equipment used extensively in
the pharmaceutical industries to reduce the moisture content of pharmaceutical powder and
granules. The equipment works on a principle of fluidization of the feed materials.
Rotary wet granulator adopts the wet granulation method. With a certain amount of water
or steam, there will be chemical reactions in the cylinder. The rotating of cylinder will make the
materials squeeze. And then materials will become pellets under a certain liquid condition.

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Figure: Oscillating granulator
Figure: Fluid bed dryer

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Figure: Rapid Mixing Granulator (RMG)
Figure: Rotary drum wet type granulator

8. 8
For Blending: Blending is commonly described as the process of mixing two or more chemicals
together without producing a chemical reaction. Many consumer and cosmetic products containing
industrial chemicals are mixtures formed by blending.
Double Cone Blender is superlative for mixing dry powder and granules homogeneously. The
blender is highly preferable in a number of industrial blending applications due to its easy
functioning, cleaning, discharging and contamination absence.
The Octagonal Blender with its octagonal shaped mixing bin and built-in baffles ensures
efficient blending. It is ideal for gentle blending of dry granules or powder.
V Cone Blender is a machine equipped with two inclined cylinders (vessels or barrels) fixed
together at an angle 70°C to 90°C to form a conical "V" shape. In the shell when rotates, materials
are divided and then mixed together.
Figure: Octagonal blender

9. 9
Figure: Double cone blender
Figure: V cone blender

10. 10
For Milling: Milling is the process of grinding, cutting, pressing, or crushing a material in a
special machine. Milling is the process of cutting away material by feeding a workpiece past a
rotating cutter with many teeth.
Jet mill: A jet mill grinds materials by using a high-speed jet of compressed air or inert gas to
impact particles into each other. Jet mills can be designed to output particles below a certain size
while continuing to mill particles above that size, resulting in a narrow size distribution of the
resulting product.
Hammer Mill: A hammer mill is a mill whose purpose is to shred or crush aggregate material
into smaller pieces by the repeated blows of little hammers.
Multi-Mill: It operates on the principle of variable force swing beaters having both knife and
impact edges rotating within a selected screen to get the required size reduction.
Figure: Multi-mill

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Figure: Jet mill
Figure: Hammer mill

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For Compression: Pharmaceutical compression process is an important part of pharmaceutical
tablet manufacturing. Where upper and lower punches bringing together under pressure within the
die to form the tablet. As the punches enter the compressing stage, the upper and lower punches
move between two large wheels called pressure rolls.
Figure: Compression machine
Figure: Tablet press machine

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For Coating: Tablet coating is the process where coating material is applied to the surface of
the tablet to achieve the desired properties of dosage form over the uncoated variety. There are
three main processes for tablet coating: sugar coating, film coating, and enteric coating.
Fluid bed granulator and coater: The coating solution is sprayed on the rolling cores
through the pump and spray gun. The process involves simultaneous coating and drying of the
cores.
Sugar coating machine: The sugar coating machine is mainly used for coating and polishing
the shaped tablets and micro granules in confectionary and pharmaceutical industry. It can also be
used to coat nuts, dried fruit, and seeds etc.
Fluid bed coater: This equipment is used for enteric coating. Fluid Bed Coater is a new
type coating equipment that combined fluid bed spray technology and coating well. It is widely
used for film slow and control releasing coating, framework slow and control releasing capsule,
pellet coating, granules and powder coating.
Figure: Fluid bed granulator and coater

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Figure: Fluid bed coater (enteric coating)
Figure: Sugar Coating Pan

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For Powder: Powder auger fillers are machines that you can use in filling powdered products
into sachets, stick packs and pillow bags. One can use the machine to fill and package different
powder products such as cocoa, spices, and milk powder among others.
Figure: Powder auger filler

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For Capsule: SaintyCo SF-25 semi-auto capsule filler is a modern equipment that guarantees
an ultra-quiet operation with a noise level of 70dBA. It can be customized depending on capsule
sizes by adjusting the rotation of the dosing disc. To achieve accurate filling process, SaintyCo
SF-25 semi-automatic capsule filler uses an agitator in the powder feeder to regulate the filling
process.
Figure: Semi-auto capsule filling machine
Figure: Fully automatic capsule filling machine

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For Blister Packing: SaintyCo BP 150 Alu Alu Blister Packing Machine is a robust and GMP
compliant machine featuring a modular and compact concept. It is a small size machine that
optimizes blister packing process in a limited working space. The flexible design of SaintyCo BP
150 Alu Alu Blister Packing Machine ensures easy part changeover and adjustments. Depending
on Alu Blister packing needs, it is easier to incorporate pre-cutting, extended feeding area, printing,
automatic feeder and inspection systems.
Figure: Alu-alu blister packing machine

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For Strip Packing: Strip packing machine is extensively used to pack tablets, capsules,
caplets, coated tablets, soft gelatin capsules.
Advanced strip packing: The range of machines produce high quality 4 side sealed packs.
The packaging materials are fed from 2 reels to the sealing station where the products are fed
precisely timed in between the 2 layers of foil before being sealed together by temperature and
pressure.
Figure: Advanced strip packing machine

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Conclusion:
Solid dosage forms have been one of the foremost choices of drug administration for generations.
However, with an ever-growing global population, evolving customer demands and continual
updates to regulations comes greater need for advanced medicines and progress in this sector. This
article explores the benefits and how the field must develop to maintain dominance in the sector.