A tablet with ideal traits is not the result of being manufactured on a tablet press. It is actually made in the granulation process. Granulation is the process of collecting particles together by creating bonds between them. When particles are joined during a specific granulation process, the result is an improved flow and compression traits, less segregation, unproved uniformity of the content, and it gets rid of excess amounts of fine particles. The result is improved yields, reduced tablet defects, a boost in productivity, and a significant reduction in down time.

All over the world, pharmaceutical products are processed using the direct-compressing, wet-granulation, or dry granulation methods. When it comes to granulation manufacturing processes, new advancements in formulation technologies have resulted in conventional wet granulation processes to dry granulation processes. There are a number of benefits to dry granulation processes such as: it permits for expedition of the granulation process, a cost saving process, a time saving process, and there is much easier handling.

With the wet granulation process, the process requires multiple steps. As well, with wet granulation, compressing the lower-tray granulations may contain too much moisture which can cause the granules to adhere to the tablet-press tooling resulting in defective tablets being produced. With Direct Compression, a group of ingredients are blended, put on a tablet press, and then made into a tablet without having any of the ingredients changed. However, often the tablet will fall apart during the process, and the active ingredients will not be in all of the tablets because there is a lack of uniform content. In addition, all of the powders will not fit into the die cavity.

The dry granulation process is used to form granules without using a liquid solution. Forming granules without moisture requires compacting and densifying the powders. Dry granulation can be performed on a tablet press using a roller compactor which is normally called a chilsonator or a slugging tool can be used. With a roller compactor, an auger-feed system consistently delivers powders uniformly between two pressure rollers. The powders are compacted into small pellets or a ribbon between the rollers and then milled through a low-shear mill. When the product is thoroughly compacted, then it can be passed through a mill and final blend before tablet compression.

The dry granulation is beneficial for medium and high dose drugs. It is particularly helpful for active pharmaceutical ingredients (APIs) that are moisture and heat sensitive. There are a number of considerations when buying the necessary equipment for dry granulation tablet production. For instance, you should consider such factors as: high quality sanitary screens, gentle grinding action and fast discharge, explosion resistant electrices, special in-feed chutes, and adjustable height frame.

Choosing a method requires thorough investigation of each ingredient in the formula, the combination of ingredients, and how they work with each other. Then the proper granulation process can be applied. Due to the many benefits of the dry granulation process, more pharmaceutical products are now being processed using dry granulation methods.

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