Continuous Tablet Molding and Coating With Rotating Core Blocks

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Solution Overview

Problem

Existing methods for producing coated pharmaceutical tablets by injection molding are discontinuous, lacking a suitable platform for continuous manufacturing, which hinders efficiency in the pharmaceutical industry.

Innovation Solution

A machine and method for producing coated pharmaceutical tablets through a continuous process, utilizing a mold unit with rotatable core blocks, a coating delivery system, and a core injection unit with a retractable piston to form temporary molds and inject hot melt and coating materials, enabling a continuous manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If injection molding is used to produce coated pharmaceutical tablets, then flexibility of shaped-part preparation and ability to eliminate batch production is improved, but the process operates discontinuously which reduces manufacturing efficiency

Engineering Contradiction:

Improveflexibility of shaped-part preparationVSAvoidmanufacturing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent implements a continuous injection molding process where the mold rotates through multiple positions, allowing injection, coating application, and ejection to occur simultaneously in different stations. This eliminates idle time between operations and maintains continuous production flow, directly resolving the discontinuity problem while preserving the versatility of shaped-part preparation

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If a continuous manufacturing process is implemented, then production efficiency is improved, but the system complexity increases due to the need for integrated molding and coating capabilities

Engineering Contradiction:

Improveproduction efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The manufacturing system is divided into distinct functional modules: injection molding unit, coating application unit, and mold rotation mechanism. Each module performs a specific function and can be independently controlled, which manages the overall system complexity while enabling continuous production through coordinated operation of these segmented components

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mold serves multiple functions by rotating through different positions: it acts as both the injection mold cavity and the coating receptacle, and also serves as the ejection mechanism. This multi-functionality reduces the need for separate dedicated equipment for each operation, thereby managing system complexity while achieving continuous manufacturing

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If discontinuous batch production is used, then device complexity is reduced, but loss of time occurs due to batch testing and production interruptions

Engineering Contradiction:

Improvedevice complexityVSAvoidbatch testing time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The continuous process eliminates batch testing interruptions by maintaining uninterrupted production flow. Tablets are produced and coated continuously without stopping for quality checks, as the process parameters remain constant throughout continuous operation, thereby reducing time loss while managing device complexity through standardized continuous manufacturing equipment

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the efficient production of coated pharmaceutical tablets in a continuous manner, improving production efficiency and eliminating the need for batch testing, while allowing for life-cycle management of active pharmaceutical ingredients.

Implementation Method 1

the retractable piston (321) is configured to retract to expand the piston barrel injection chamber (325)

Methodology Applied

Scientific EffectPiston retraction and expansion:

Implementation Method 2

extend to eject material present in the piston barrel injection chamber (325) into the second temporary mold

Methodology Applied

Scientific EffectPiston extension and injection:

Implementation Method 3

a means to provide a heated coating material under pressure

Methodology Applied

Scientific EffectPressure-driven material delivery: Pressure Increase

Implementation Method 4

a continuous source of a hot melt comprising an active pharmaceutical ingredient and one or more excipients

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS12551407B2System for molding and coating of pharmaceutical tablets

Publication Date: 2026.02.17 IMA IND MASCH AUTOMATICHE SPA

AI summary

Disclosed herein are new injection molding-coating devices for the continuous manufacturing of coated pharmaceutical tablets comprising one or more active pharmaceutical ingredients and one or more excipients. Also disclosed herein are methods for the continuous manufacture of coated pharmaceutical tablets using these new devices for the purpose application in the pharmaceutical and drug manufacturing industries.