DRUG DISCOVERY AND DEVELOPMENT 37
The importance of tablet shape
Dale Natoli investigates the complexities of deciding on tablet shape.
W
hy that tablet shape? Tis is a question often asked, especially
when researching a solution to a tablet or tooling deficiency directly related to a tablet shape.
Most companies do their due diligence when selecting a tablet shape, and some simply only lack the understanding of the importance of tablet shape and its effect on efficiency.
An improper tablet shape can cost millions in lost production and sometimes even cause a complete disaster.
Some companies design unique tablets hoping to reach an acceptable level of consumer recognition with the objective to maintain customer loyalty; this effort is generally driven by marketing. Tablets are designed
Fig. 1. Powder extrusion in a flat face design.
considering the end user, such as a ‘break-easy’ bisect design or a child’s three-dimensional animal shaped multivitamin. Tablets are designed for technical application such as watch batteries and automotive airbag igniters, pre-formed desiccants, and so on.
However, some companies desire a tablet shape engineered to provide easy and unobstructed production such as a simple standard cup round.
Certain tablet shapes simply play havoc with tooling and press wear – adding significant costs to the unit dose. Te same is true with packaging, as an incorrect tablet design can chip, clog or provide an improper tablet count related to weight.
An error commonly made when considering a tablet shape is replicating and even duplicating a poor design. Unfortunately
this happens often within a company’s own product portfolio as well as in the attempt to replicate or duplicate an existing tablet that is considered to be a weak and deficient design.
One of those happens to be one of the oldest and most common tablet designs – and one that is still used today. Tis is the Flat Face Bevel Edge configuration, commonly referred to as the FFBE.
Te FFBE was designed as an alternative to the most common Flat Face design. At the onset of commercial tablet manufacturing, the industry sought out ways it could rectify a well-known issue with Flat Faced tablets, which was edge attrition. Te problem was created as the flat face tool entered into the compression cycle. Te FF design naturally pushed or forced the powder to the outside perimeter of the
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