Deformable Wax Coated Particles for Tablet Compression
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Solution Overview
Problem
When particles containing active ingredients for tablets are compressed, some essential ingredients are squeezed out, degraded, or lost, leading to initial loss and potential issues like smell or discoloration, necessitating over dosage to ensure the correct amount in the final product.
Innovation Solution
A process for producing coated particles using a top spray method with a coating system comprising wax and/or fat, where the coating layer is deformable and irregular in thickness, and contains vacuoles, to minimize initial loss during compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating methods are used to protect active ingredients, then the coating provides a protective layer, but the coating is too rigid and causes active ingredients to be squeezed out during compression
Solution Approach 1:
The patent changes the physical and chemical parameters of the coating material by using waxes and fats with specific melting points (30-85°C) and incorporating plasticizers. This transforms the coating from a rigid structure to a deformable, irregular thickness coating with vacuoles that can accommodate compression forces without squeezing out active ingredients
Solution Approach 2:
The patent creates a composite coating system combining waxes (e.g., carnauba wax, candelilla wax, sugarcane wax) and fats (e.g., hydrogenated palm oil, coconut oil) with plasticizers and optional pigments. This composite structure provides both protection and deformability, resolving the contradiction between protective function and rigidity
2Reliability
If uniform thick coating is applied to prevent ingredient loss, then protection is improved, but the coating prevents proper compaction and tablet formation
Solution Approach 1:
The patent deliberately creates an asymmetric, irregular thickness coating where the coating layer varies in thickness across the particle surface (0.1-10 μm average, with local variations). This irregular structure allows different regions to deform differently during compression, enabling proper tablet formation while maintaining protection
Solution Approach 2:
The patent incorporates vacuoles (air pockets or voids) within the coating structure, creating a porous network that allows the coating to compress and deform during tablet formation. These vacuoles act as cushioning spaces that collapse during compression without forcing active ingredients out
3Quantity of substance
If over dosage is used to compensate for initial loss, then the correct amount of active ingredient is ensured in final product, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies preliminary protective action by coating the active ingredient particles with the deformable wax/fat coating before compression. This pre-protection prevents initial loss during the subsequent compression process, eliminating the need for over dosage and simplifying the manufacturing process
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
The coated particles exhibit reduced initial loss during compression into tablets, maintaining the desired amount of active ingredients and preventing issues like smell or discoloration, without the need for over dosage.
Implementation Method 1
An atomizing air pressure of 1 bar and an atomizing air temperature of 100 to 120° C. were used for the entire process
Data Source
AI summary
The present patent application relates to coated particles. These coated particles show improved properties when used in compressed tablets.