Automatic Tablet Coater- Film & Sugar Coating

Application & Process

Application:

The Prism’s advanced tablet coating machine is a high-efficiency, energy-saving, and safe equipment for film and sugar coating of pharmaceutical and food products. It features mechatronics technology, meets cGMP requirements, and supports aqueous and non-aqueous coatings, including enteric and non-enteric film coatings. It’s a versatile solution that ensures optimal productivity and exceptional product quality.

Process:

The tablet undergoes a continuous and intricate orbital motion within a closed rotating drum, guided by a streamlined arrangement of baffles. As per the predetermined technological process and optimal parameters, the coating medium is automatically sprayed onto the tablets. Simultaneously, hot filtered air is supplied under negative pressure.

This heated air permeates through the layers of the tablet, effectively drying the sprayed coating medium uniformly. Consequently, a solid and smooth surface film is formed, resulting in a high-quality coated tablet. The entire process is seamlessly controlled by an advanced PLC system, featuring a user-friendly touch screen interface.

Drum Geometry:

• Compact design, allowing for efficient use of space.
• Large spray area with a high number of nozzles, ensuring comprehensive coverage during the coating process.
• Rapid and effective mixing of the tablets, both horizontally and vertically, for consistent and uniform coating.
• Easy and thorough cleaning facilitated by dedicated cleaning nozzles, saving time and ensuring hygiene.

Mixing Elements:

• Leveraging years of expertise in mixing technology, Prism has introduced highly efficient mixing baffles for their Coater. These innovative baffles are designed for easy cleaning and enable a remarkable filling level flexibility, ranging from approximately 20% to 100% of the working volume. This means that the coating drum does not need to be replaced when adjusting the filling level, while ensuring gentle handling of the product.
• When the coater drum runs in reverse, all tablets are swiftly and completely discharged through a dedicated opening on the front door of the coater. This seamless process is facilitated by special discharge elements, eliminating the need for any additional discharge aids.

Nozzle Arm:

• The Coater incorporates a specially designed nozzle arm that offers adjustable positioning on two pivot axes, which can be motor-driven if desired. This unique mechanism allows for an extensive range of nozzle adjustments, effectively utilizing the 20-100% filling level variability. As a result, various batch sizes can be produced without the need for drum changes.
• The Coater is equipped with an optimal number of nozzles, ensuring an ideal spray pattern and maximum coverage across the entire spray area. The coating solution is uniformly applied, resulting in consistent coating quality.
• Depending on the pump version, the fluids can be delivered to the nozzles either through a single line or through individual lines for each nozzle, allowing for flexible configuration.
• For enhanced precision and control, an optional laser measuring technology can be utilized to measure the position of the nozzles. This feature enables reproducibility and even the ability to control the exact positioning of the nozzles for precise coating application.

Salient Features

• Designed in compliance with cGMP standards, featuring product contact parts made of AISI 316 stainless steel.
• Capable of film and sugar coating for tablets using aqueous, non-aqueous, enteric, and non-enteric solutions.
• Equipped with a variable speed drive through VFD for the perforated pan, ensuring flexibility in operation. The machine has a sturdy structure with a wash sink, air plenum, and front and side doors.
• Advanced PLC controls with an intuitive HMI touch screen interface for seamless operation.
• Incorporates baffles for excellent mixing and tumbling performance.
• Includes a spray system with a peristaltic pump, atomized spray gun, and solution tank for efficient coating application.
• Features an inlet air handler with pre-filter, blower, dehumidify coil, heat exchanger, final filter, and HEPA filter for clean air supply.
• Equipped with an exhaust air blower and scrubber to effectively eliminate air pollution. Tablet discharging is facilitated through a special diverter assembly integrated with the CIP/WIP system for easy cleaning.
• Designed with explosion-proof construction for enhanced safety.
• Provides provision for adjusting the angle of the spray gun as per requirements.

Safety Features

• Nozzle/Spray arm close interlocking.
• Temperature control based on PID control using PLC control logic.
• Dampers open/close feedback using proximity sensor.