Tablet Defects

Tablet Defects in Pharmaceutical Manufacturing, How it can be Prevented?

Tablet Defects- Tablets are an important dosage form for many pharmaceutical products. They are easy to administer and have good patient compliance. However, the manufacturing process of tablets is complicated and can often result in defects. This article will discuss some of the most common tablet defects and their causes.

Tablet Defects in Pharmaceutical Manufacturing
Photo by Alex Green on

What is Tablet?

A tablet is a pharmaceutical dosage form designed to be taken orally. Tablets may contain active ingredients, excipients, or a combination of both. Active ingredients are substances that produce the desired pharmacological effect. Excipients are inactive substances that bind, fill, coat or disintegrate the active ingredient.

Tablets are manufactured by various processes, which may be grouped into two main categories: direct compression and granulation. Direct compression is the simplest and most common method of tablet manufacturing. Granulation is a more complex process typically used when direct compression is not possible or desirable.

Tablets may be coated with various materials to enhance their appearance, stability, dissolve rate, and taste. Common coating materials include sugar, shellac, and enteric coatings.

Tablets are designed to be taken orally and must therefore be designed to resist degradation in the stomach and intestine. In addition, tablets must be designed to disintegrate rapidly to release the active ingredient for absorption in the body.

What is Oral Drug Delivery System?

An oral drug delivery system is a system used to deliver medication orally. The medication can be in the form of a pill, capsule, or liquid. The system includes a way to measure the correct dose of the medication and deliver the medication to the patient’s mouth.

Oral drug delivery systems are used to deliver medication to patients who cannot take medication by mouth or who have difficulty swallowing pills. They are also used to deliver medication to children and to people who have a fear of needles.

What are tablet Defects?

It is common in the pharmaceutical manufacturing process and can occur for various reasons. Defects can be caused by problems with the ingredients, the manufacturing process, or the tablet presses. Common defects include cracks, chips, and voids.

Tablet defects can cause serious problems for pharmaceutical companies. First, defective tablets may not meet the quality standards set by regulatory agencies. This can lead to delays in getting new products to market or even recalls of existing products. Second, defective tablets can cause customer satisfaction issues. Poorly made tablets may not work as intended, leading to negative reviews and lost sales.

Fixing tablet defects is crucial for any pharmaceutical company. To prevent defects, companies must carefully control every aspect of the manufacturing process, from ingredient selection to tablet press maintenance. Inspections at every production stage can help catch potential problems before they result in defective tablets. When defects occur, companies must take steps to correct the issue and prevent it from happening again.

Causes of tablet Defects

There are many potential causes of tablet defects in pharmaceutical manufacturing. Some of the most common include:

  1. Poor quality raw materials This is often the most common cause of tablet defects. If the raw materials used in the manufacturing process are of poor quality, it will likely result in defective tablets.
  2. Incorrect mixing of ingredients If the ingredients are not correctly mixed, it can result in an uneven distribution of the active ingredient(s) and excipients. This can lead to tablet defects such as poor disintegration, poor dissolution, and poor Bioavailability.
  3. Poor compression If the tableting process is not carried out correctly, it can result in poorly compressed tablets. This can cause tablet defects such as crumbling, chipping, or flaking.
  4. Poor ejection from the die During the tableting process, if the tablets are not ejected properly from the die, it can cause them to be deformed or have an uneven surface.
  5. Improper storage or transportation If the tablets are not stored or transported under proper conditions, it can lead to physical or chemical changes that may result in tablet defects.
  6. Poorly designed manufacturing process – A poorly designed manufacturing process can also lead to tablet defects. If the process is not optimized, it can result in problems with the finished product.
  7. Equipment malfunction – Another potential cause of tablet defects is equipment malfunction. If the equipment used in the manufacturing process is not working properly, it can lead to defects in the finished product.
  8. Human error – Finally, human error can also be a cause of tablet defects. If the people involved in the manufacturing process make mistakes, it can result in defective tablets.

How to prevent tablet Defects?

It is one of the most common problems in pharmaceutical manufacturing. While there are many causes of tablet defects, there are a few key ways to prevent them.

Tablet Press

First, it is important to have a well-designed tablet press. A good tablet press will have features that minimize the chances of defects, such as adjustable punches and dies and proper tooling and alignment.

Raw Material Quality

Second, the quality of the raw materials used to make the tablets is critical. Using lower quality materials can increase the chances of defects.

Controlled Conditions

Third, the manufacturing process must be carefully controlled. All steps in the process must be followed exactly to avoid defects. This includes everything from mixing the ingredients to pressing the tablets to package them.

Regular Maintenance

Fourth, regular maintenance of the equipment is essential. Tablet presses and other machinery must be cleaned and maintained according to manufacturer specifications to prevent problems.

By following these four steps, tablet defects can be greatly reduced or even eliminated.

What Happens When a tablet has defected?

It is one of the most common problems in pharmaceutical manufacturing. While there are many causes of tablet defects, some of the most common include incorrect ingredients, incorrect proportions of ingredients, and poor mixing. Tablet defects can also be caused by environmental factors such as humidity and temperature.

When a tablet is defective, it can cause several problems for the patient. In some cases, the tablet may not dissolve properly, which can cause it to be ineffective. In other cases, the tablet may dissolve too quickly, which can cause an overdose. Tablet defects can also cause the tablet to break down into smaller pieces, which can be a choking hazard.

If you suspect that your medication may be defective, it is important to contact your pharmacist or doctor immediately. They will be able to advise you on whether or not you should continue taking the medication. In some cases, they may also be able to provide you with replacement medication.

It is a serious problem and should not be taken lightly. If you think that your medication may be defective, contact your pharmacist or doctor immediately.

Solutions to tablet Defects 

Many pharmaceutical companies are now turning to blogs to communicate with their customers and promote their products. While most blogs focus on general topics related to the industry, some are specifically devoted to solving defects in tablet manufacturing.

These blogs can be extremely helpful for those struggling with defects in their production process. By reading about the experiences of others, it is possible to learn about new solutions and find the inspiration needed to overcome these challenges.

If you are looking for a way to connect with other professionals in the pharmaceutical industry, or if you want to stay up-to-date on the latest news and developments, then starting a blog may be the right solution for you.

Tablet defects are a common problem in the pharmaceutical industry. While there are many potential causes of tablet defects, there are also many ways to solve them.

How to Report the Tablet Defects?

When it comes to tablet defects in pharmaceutical manufacturing, it is important to know how to report them. This way, you can help ensure that the issues are addressed and corrected as soon as possible. There are a few different ways that you can report tablet defects, including:

-Through the company’s internal quality control system

-To the FDA, through their MedWatch program

-To an independent testing laboratory

Each method has its own advantages and disadvantages, so it is important to choose the one that makes the most sense for your situation. For example, reporting to an independent testing laboratory may be the best option if you are concerned about potential legal repercussions. On the other hand, if you want to be sure that the company is aware of the issue and is taking steps to correct it, going through the internal quality control system may be the better choice.

No matter which method you choose, providing as much information as possible about the defect is important. This includes when and where it was found, the batch it came from, and the steps taken to address the issue. The more information you can provide, the easier it will be for whoever is investigating the defect.


Tablet defects are a common occurrence in pharmaceutical manufacturing. While most defects are minor and do not affect the quality of the finished product, some can be more serious and cause the tablet to be ineffective. Identifying tablet defects early on is important so that corrective action can be taken to prevent them from occurring in the future. By understanding what causes tablet defects, manufacturers can take steps to avoid them and produce a higher quality product.

Read More: What is Sustained-release tablets?

2 thoughts on “Tablet Defects in Pharmaceutical Manufacturing, How it can be Prevented?

Leave a Reply