Tiffany Haney
The capacity of a coating pan is calculated to achieve a uniform coating. The working capacity of the coating machine is determined by the brim volume of the coating pan, which is the total volume of water when the pan is fully filled. The maximum capacity of the pan is calculated by multiplying the brim volume by the bulk density of the tablets. Pan speed, spray rate, air flow, and inlet temperature are other factors that play a role in the coating process.
| Characteristics | Values |
|---|---|
| Factors affecting coating pan occupancy | Quantity of tablets, pan load, pan speed, spray rate, air flow, inlet temperature, number of spray guns, drying capacity, bulk density of tablets |
| Calculation of maximum capacity of coating pan | Brim Volume (in litres) x Bulk Density of Tablets (in mg/ml) |
| Calculation of minimum capacity of coating pan | 60% of the maximum capacity |
| Calculation of working capacity | 50% to 90% of total pan capacity |
| Pan RPM calculation | Refer to Equation 4 |
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What You'll Learn
Brim volume and bulk density
Brim volume refers to the total volume of water that a coating pan can hold when it is completely filled with water at its current position. It is important to note that the brim volume is not the same as the total volume of the pan. The brim volume is typically provided in the equipment manual.
Bulk density, on the other hand, pertains to the tablets themselves. It represents how much space the tablets occupy in the coating pan and is influenced by their shape and size. Smaller tablets of the same formulation tend to have a higher bulk density compared to larger tablets.
The maximum capacity of the coating pan is calculated by multiplying the brim volume (in litres) by the bulk density of the tablets (in mg/ml). This calculation ensures that the pan is filled to its maximum capacity with the appropriate number of tablets. The formula for maximum capacity is:
Maximum Capacity of Coating Pan (Kg) = Brim Volume (ltrs) X Bulk Density of Tablets (mg/ml)
Additionally, the minimum capacity of the coating pan is calculated as 60% of the maximum capacity. This calculation takes into account the fact that the coating pan should not be filled to its absolute maximum every time. The formula for minimum capacity is:
Minimum Capacity of Coating Pan (Kg) = Brim Volume (ltrs) X Bulk Density of Tablets (mg/ml) X 60/100
By understanding and applying these calculations, manufacturers can ensure that the coating pan is utilised efficiently, resulting in optimal coating results for tablets of varying shapes and sizes.
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Pan load
The pan load is a critical factor in achieving optimal coating results. It refers to the weight of the tablets in the coating pan, which is crucial in determining the working capacity of the coating machine.
The maximum capacity of the coating pan is calculated by multiplying the brim volume (the volume of water when the pan is fully filled) by the bulk density of the tablets. This value is typically provided in the equipment manual. For example, if the brim volume is 400 litres and the bulk density of the tablets is 0.6 gm/ml, the maximum capacity of the coating pan is 240 kg.
The minimum capacity of the coating pan is generally accepted to be 60% of the maximum capacity. In the previous example, the minimum capacity would be 144 kg.
Maintaining the appropriate pan load is essential for achieving uniform coating. An insufficient quantity of tablets in the pan can lead to coating problems, such as non-uniform thickness, which can impact the delivery rate of the active pharmaceutical ingredient. Therefore, it is crucial to calculate and adhere to the recommended pan load to ensure effective coating results.
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Pan speed
The speed of rotation of the coating pan affects the mixing of the tablets inside. Both axial and radial mixing are important to ensure that all the tablets spend a similar amount of time in the spray zone, receiving a consistent coating. Axial mixing improves with increasing pan speed, and it is the most critical factor in affecting coating variability. However, it is important to note that while axial mixing is better at higher pan speeds, it does not significantly impact coating variability.
The effect of pan speed on coating uniformity was studied in various experiments. One such experiment found that pan speed had the largest effect on coating uniformity, followed by spray rate, inlet temperature, and the number of spray guns. Another study, which used computational methods to simulate the movement of tablets in the pan, also found that pan speed was the most significant factor related to coating uniformity.
It is important to determine the optimal pan speed to achieve the desired coating uniformity and ensure that all tablets receive a similar coating. This can be done through practical scale-up rules that do not require complex experimentation. By implementing these rules and studying the effects of the key process variables, manufacturers can ensure a consistent and efficient coating process for tablets.
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Spray rate
The spray rate is a critical factor in achieving uniform coating thickness. A higher spray rate can be achieved by increasing the temperature, but this depends on the sensitivity of the coating material. The spray rate also affects the weight gain of the tablets during coating. When the number of spray guns was increased from one to two, the weight gain variation was reduced.
The spray rate also influences the membrane roughness of the coating. The size of the spray droplets and the velocity of the spray affect the membrane roughness and opacity, respectively. The droplet size is determined by operational conditions, such as spray angle and velocity.
To improve the inter-particle coating uniformity, a lower spray rate, filling ratio, and higher pan speed are recommended. The spray angle and particle size also play a role in reducing inter-particle coating variability. The spray rate, along with pan speed, inlet temperature, and number of spray guns, are important variables that influence the overall coating uniformity.
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Airflow
The airflow rate must be kept constant during the coating process. This is particularly important for functional coatings. As the process is scaled up, the airflow scale-up must be in coordination with the spray rate scale-up. This is because a five-fold batch size increase may only allow a two-fold increase in process air. Therefore, the product temperature should be kept constant across scales.
The drying kinetics of the coating process can be controlled by adjusting the temperature. However, this depends on the sensitivity of the coating material and its film-forming properties. The spray gun positioning, relative to the bed and the inlet air plenum, will also affect the drying process of the spray droplets. The distance of the spray gun from the bed, atomisation/fan air pressures, and nozzle type/diameter are factors that influence the drying process.
The number of spray guns used in the coating pan is also important. The number of guns should be selected to ensure the full width of the tablet bed is covered with spray. The distance between the coating guns should be fixed to avoid overlap.
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Frequently asked questions
The formula for calculating the maximum capacity of a coating pan is: Maximum Capacity of Coating Pan (Kg) = Brim Volume (ltrs) X Bulk Density of Tablets (mg/ml).
The minimum capacity of a coating pan is 60% of the maximum capacity.
The working capacity of a coating pan is calculated by multiplying the brimful volume of the coating pan with the bulk density of the tablets.
Pan speed, spray rate, inlet temperature, and the number of spray guns all affect the coating uniformity of a pan.
