Volume 135 - Tableting vs Encapsulation in Oral Drug Products

Manufacturing Basics: Tableting and Encapsulation

What are Tableting and Encapsulation?

Two of the most common formulations for oral drug products are tableting and encapsulation.

Tableting is the method of pressing loose materials into a small, hard pill. At a high level, the powder or granule mixture is prepared and filled into a mold. Once in the mold, a tablet press compresses the loose material into a tablet. After compression, tablets are often coated to protect the tablet from the environment, change the taste/smell, or to alter the release of the drug (i.e. extended release). Tablets must be made of a uniform mixture and consistent size to achieve consistency of the dose from pill to pill.

As opposed to compressing the medicine into a tablet, encapsulation provides a "shell" in which the medicine is enclosed. Capsules can be hard-shelled or soft shelled. The hard-shelled capsules contain dry, powdered ingredients or small pellets whereas soft-shelled capsules are mainly used for oils and active ingredients suspended in oil (ex. fish oil supplements).

How Automated Tableting and Encapsulation Work

Tableting Diagram

Watch this video to see a tablet press in action!

Tableting

  1. Powder/granules are fed into each of the cavities on the tablet press. (Note: In this image the drug product is represented in orange.)
  2. The scraper levels off the powder in the cavity.
  3. Each cavity is checked for weight prior to compression.
  4. The upper punches move downward and the tablets are pre-compressed with a smaller roll.
  5. Tablets are fully compressed into their final form with the main compression roll.
  6. The punches move apart, and the tablet is ejected from the press. They are de-dusted and run through a metal detector. If applicable, the tablets are then coated using a tablet coater.
Encapsulation Diagram

This video shows an encapsulation machine operating.

Encapsulation

  1. Capsules are fed into the segments and separated via suction.
  2. Separated capsules are transported to the first station.
  3. Separated capsules are transported to the second station.
  4. Powder is inserted into the capsule. (If applicable.)
  5. Pellets or micro tablets are filled into the capsule. (If applicable.)
  6. Faulty or defective capsules are rejected.
  7. The body and cap are joined to re-form the capsule.
  8. The body and cap are locked together.
  9. The finished capsules are ejected and drop through the duster before falling into the drum of bulk drug capsules.

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