Spherical Confectionery Granules for Tablet Compression
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Solution Overview
Problem
Existing methods for manufacturing tablets using granules face issues such as lump formation, non-homogeneous distribution of ingredients, irregular granule shapes, and the inability to incorporate water-soluble active ingredients, leading to friable tablets with poor flow and visual inconsistencies.
Innovation Solution
The use of substantially spherical granules with a sweetener core coated by smaller sweetener particles using an aqueous hydrocolloid solution, allowing for the creation of tablets with a visually varied surface and enabling the inclusion of water-soluble active ingredients by correlating granule colors with specific ingredients, ensuring homogeneous distribution and optimal compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If granular ingredients are pre-mixed and compressed using conventional granulation techniques, then tablets can be manufactured, but lumps form that prevent or interfere with the compression process
Solution Approach 1:
The invention changes the particle size parameter by using very small granules (average size 0.5-2 mm) instead of conventional larger granules. This parameter change prevents lump formation during compression while maintaining manufacturability. The fine granule size allows for uniform distribution and compression without forming harmful lumps.
Solution Approach 2:
The invention uses a sorbitol syrup binder that replicates the binding function of hydrocolloids without requiring them. The syrup creates appropriate adhesion between granules during granulation, enabling tablet formation without the lump formation problems associated with conventional hydrocolloid-based binders.
2Object-generated harmful factors
If drying steps are used to remove water content, then lump formation is prevented, but water-soluble active ingredients cannot be used
Solution Approach 1:
The invention uses a soluble binder (sorbitol syrup) that dissolves during compression rather than forming permanent lumps. This temporary binding mechanism allows water-soluble active ingredients to be incorporated without causing lump formation, as the binder dissolves and redistributes the ingredients uniformly during the compression process.
Solution Approach 2:
The invention changes the binder properties from hydrocolloid-based (requiring drying) to syrup-based (soluble). This parameter change in binder solubility allows water-soluble active ingredients to be used without causing lump formation, as the syrup binder dissolves during compression rather than requiring prior drying steps.
3Ease of manufacture
If irregularly-shaped granules are used, then material can be compressed into tablets, but gaps are generated between granules resulting in excessively friable tablets
Solution Approach 1:
The invention uses small granules with regular, near-spherical shapes instead of irregularly-shaped granules. This spheroidality improves packing efficiency and reduces gaps between granules during compression, resulting in tablets with greater strength and reduced friability while maintaining ease of manufacture.
4Ease of manufacture
If irregular granule sizes are used, then granulation can proceed, but material flow towards the compression chamber is suboptimal
Solution Approach 1:
The invention changes the granule size parameter to very small dimensions (0.5-2 mm average size) with narrow size distribution. This parameter change optimizes both granulation feasibility and material flow characteristics, enabling smooth, rapid flow towards the compression chamber while maintaining ease of manufacture through conventional granulation processes.
5Ease of manufacture
If random distribution of ingredients is used, then mixing is simple, but verification of formulation is difficult and tablets contain different amounts of active ingredients
Solution Approach 1:
The invention changes the particle size parameter to very fine dimensions, which transforms the distribution pattern from random to uniform at the macro scale. This parameter change enables simple mixing while achieving homogeneous distribution, allowing easy verification of formulation and consistent active ingredient content across all tablets.
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
This approach results in tablets with a smooth, visually appealing mosaic effect, ensuring accurate ingredient distribution and compatibility, and producing tablets with improved flow and mechanical stability, allowing for the inclusion of previously incompatible ingredients.
Implementation Method 1
said particles being caused to adhere to the core by an aqueous solution of a suitable hydrocolloid
Data Source
AI summary
Disclosed is a process for the manufacture of a confectionary product consisting of a tablet characterised by the use of water-soluble ingredients.