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Copyright © Keva Pharmaceuticals
TROUBLESHOOTING OF
COMPRESSION ISSUES
Presenter: Suraj Kumar Sah
25th July , 2023
Keva Pharmaceuticals Pvt. Ltd., Ratnanagar-16, Chitwan
1

Before We Start
What is Compression?
Compression Machines at Keva Pharmaceuticals…
Factors affecting compression…
Problems faced during compression…
Impacts of compression…
2

Outline
1.Introduction
2.Factor affecting compression
3.Problem faced during compression
4.Impact of compression
5.Conclusion
6.References
7.Q & A
3

Introduction
Compression: According to USP When we apply any force to powder bed then
bulk volume will be reduced, known as Compression.
The reduction in the bulk volume of a material as a result of the removal of void
space by applied pressure.
CONSOLIDATION:
Involves an increase in the mechanical strength of a material resulting from
particle-particle interactions.
COMPACTION:
The compression and consolidation of granules due to an applied force, known as
Compaction.
4

Factor Affecting Compression
Surface Properties
Porosity
Flow Properties
Compression Force
Compression Speed
Moisture Content
5

• 1. Capping
• 2. Lamination
• 3. Cracking
• 4. Chipping
• 5. Sticking
• 6. Picking
• 7. Mottling
• 8. Double Impression
• 9. Weight Variation
• 10. Hardness Variation
• 11. Friability
PROBLEM
FACED
DURING
COMPRESSION
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Capping
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Causes:
Due to the air entrapment
during compression.
Low moisture in granules.
Deep concave punches.
Remedies/Solution:
Precompression, Reducing the
final compression pressure.
Dry the granules properly.
Use flat punches.
Partial or complete separation of top or
bottom crown of tablet.

Lamination
Separation of a tablet in to two or more distinct horizontal layers.
Causes:
• Too much compression pressure.
• Unwanted dried granules.
Remedies:
Accurate compression force should be apply to form tablet.
Add hygroscopic substances certain % of moisture by
e.g. Sorbitol, Methylcellulose, PEG.
8

Cracking
• Small, fine cracks observed on the upper and lower
central surface of tablets.
Reason:
 Deep concave punches.
Too dry granules.
Remedies:
Using Flat punches.
Moisten the granules properly.
9

Chipping
• Breaking of tablet edges, while the tablet leaves the press or during subsequent
handling.
• Reason:
Incorrect machine settings/ Less Binder
Remedies:
• The Causes and Remedies of chipping related to ‘Formulation’
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Sr. No. CAUSES REMEDIES
1. Machine RPM too fast Reduce machine speed
2. Too dry granules Increase the moisture content of granules.
3. Scratch/uneven Surface Smooth punch
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Sticking
Sticking is the problem where the material adhere to die wall during tablet
compression.
Reason: Fig: Sticking on
punch Face.
 Pressure applied is higher.
 Excessive moisture in granules.
 Rough die surface.
Remedies:
Decrease the pressure to optimum.
 Proper drying of granules.
Adding glidant and lubricants.
11

Picking
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Material adhere to punch faces
 Picking is the term used when a small
amount of material from a tablet is sticking
to and being removed off from the tablet
surface by a punch face.This occurs
predominantly in upper faces of the
punches.

Picking
CAUSES
Excessive moisture in granules
Improper lubrication
Low melting point substances added
Rough or scratched punch faces
REMEDIES
Drying of granules
Increasing lubrication
Use high melting point lubricants
Platting of punch faces by - Chromium
13

Mottling
• Mottling is the term used to describe an unequal distribution of color on a
tablet.
Causes :
• Different colors of excipients or a drug
• Migration of dyes to the surface of granules during drying
• Improper mixing of color
Remedies:
• Change the solvent system (binding system)
• Reduce the drying temperature
• Mix properly and reduce the size to prevent the mottling.
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Double Impression
 Due to free rotation of the punches, having some engraving on their faces.
 Reasons For Double impression:
Uncontrolled rotation of either upper punch or lower punch during ejection of a
tablet.
 Solution/Remedies:
• Use of keyed punches.
• Use of Anti-Turning Devices.
15

Weight Variation
The tablets of one particular batch should have uniformity in weight. If any
weight variation is found, it should fall within the prescribed limits.
Tablet forms with different weight.
Causes:
Improper feeding of hopper, Poor flow, Lack of glidant and lubricant.
Remedies: Add sufficient amount of glidants and lubricants, proper the amount of
binder, uniform granules/mixing.
16

Hardness Variation
• Tablets having different hardness value. Generally, as granules size increases,
tablets are found to show increased weight variation, and same occur with the
hardness.
Causes :
• Improper binder concentration and uniformity.
• Room temperature and RH.
• Remedies:
Ensure proper amount and uniformity of binder.
During compression, maintain room temperature and RH.
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Friability
 Friability is the tendency of a tablet to crumble or break when subjected to
mechanical stress. The causes of high friability include inadequate binder,
Improper drying of granules, and tablet hardness.
 The remedies for high friability include: control of binder, moisture and
compression pressure.
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Conclusion
These visual defects can reduce the acceptability by the users and patient
compliance of the product. In this slide, defects, causes and measures to overcome
these defects have been discussed.
The focus of this discussion is to establish ways to resolve common defects
during the tablet compression, and to identify the root cause of each.
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REFRENCES
1.Lachman L., Liberman, H.A., Joseph L. K. The Theory and Practice of Industrial Pharmacy;
Varghese Publishing House; Mumbai; Third Edition 297-321.
3.Aulton M. pharmaceutics: The science of Dosage Form Design; International Student Edition:
304-321, 347-668.
4.Remington J. Remington: The Science and Practice of Pharmacy; Nineteenth Edition:Volume Ⅱ
1615-1641.
5. Ansel H., Allen L., Jr. Popovich N. Ansel’s Pharmaceutical Dosage Forms and Drug Delivery
System; Eighth Edition:227-259.
6. Mohrle R “Effervescent tablets” in Liberman, Lachman, Lachman L. Schwartz.
Pharmaceutical dosage form, “Tablets” vol-Ⅰ first Indian reprint (2005) Marcel dekkar inc New
York -285-292.
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