COATING SYSTEM FOR PHARMACEUTICAL TABLETS

Abstract

The invention relates to a novel system for applying reusable, controlled powder-liquid intermittent coatings on pharmaceutical tablets. This system 101 integrates microprocessors and sensors to regulate the coating application in multiple cycles, thereby enhancing tablet uniformity and coating durability. The unique method 102 utilizes powder-liquid alternation to minimize waste and optimize the coating's functional properties, such as controlled drug release and moisture resistance. By employing an automated control unit 103, the process achieves precision in coating thickness and consistency across large batches. The invention also includes a novel coating mechanism 104 that efficiently reduces coating time while maintaining quality. The system 105 is adjusted to coat various tablet sizes, shapes, and formulations. This technology addresses existing issues in pharmaceutical coating processes, resulting in cost efficiency and improved scalability.

Specification

Description:The present invention has been particularly shown, and described concerning certain preferred embodiment, and specific features thereof.

The following description includes the preferred best mode of one embodiment of the present invention. It is clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications, and embodiments thereto. Therefore, the present description should be seen as illustrative, and not limiting.

While the invention is susceptible to various modifications, and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit, and scope of the invention as defined in the claims.

In any embodiment described herein, the open-ended terms "comprising," "comprises," and the like (which are synonymous with "including," "having" and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

As used herein, the singular forms "a," "an," and "the" designate both the singular and the plural, unless expressly stated to designate the singular only.

The following is a step-by-step description of the invention, detailing the components, and their functionalities mentioned below:
The reusable powder-liquid intermittent coating system for pharmaceutical tablets comprises several key components and processes, each contributing to its innovative functionality. The following detailed description elucidates the structure, operation, and unique features of the invention.

1. Automated Microprocessor-Controlled System (101):
The invention is the control system, which utilizes a microprocessor to control the process of interrupted coating. Its very important role is in the adjustment of the several associated components towards proper control of powder and liquid layer application.

Components and Functionality:
Microprocessor Control Unit: Multiple sensors like temperature, humidity and pressure and actuators controlling spray nozzles and drying systems are connected to the microprocessor.
Real-Time Data Processing: The microprocessor is reading in data from the sensors constantly, so that environmental conditions and the status of the tablet being coated are monitored in real time. Algorithms have been pre-programmed into the microprocessor to dynamically control spray duration, pressure and drying times in response to changing conditions for optimal coating.
User Interface: The control panel 109 consists of an LCD display and a keypad for the operator to preset cycle times, coating thickness, and even drying temperature. Preset configurations associated with different types of tablets are stored in the system. Such configurations could be selected via the interface.
Working: The microprocessor takes the initiative to turn on the spray nozzles, and monitor the process in real time; in case of a deviation from the process, say nozzles are blocked, or coating is uneven it automatically adjusts or stops the process and prevents wastage.

2. Intermittent Coating Mechanism (102):
This invention introduces a unique intermittent coating mechanism designed to alternate between powder and liquid applications. This approach addresses the inefficiencies found in continuous spray systems, such as excessive material waste and inconsistent coatings.

Key Features:
Dual Spray Nozzle System: The coating mechanism includes two sets of spray nozzles one for powder application and another for liquid. These nozzles are mounted on adjustable arms to ensure precise targeting.
Automated Alternation: The microprocessor 101 controls the switching between powder and liquid sprays based on a set interval. This prevents oversaturation and ensures that each layer has sufficient time to dry before the next is applied.
Reduced Waste: By using intermittent spraying, the system significantly reduces material wastage. The powder layer forms a base that allows the subsequent liquid spray to bind effectively, minimizing run-off.
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3. Multi-layer Coating Capability (103):
The dispensing unit is a dual-function system capable of applying both powder and liquid coatings. For powder coatings, it uses an electrostatic spray gun 104 that charges the powder particles, ensuring even coating distribution and reducing overspray. The liquid coating system employs a series of fine nozzles 105 that create a uniform spray pattern.
Both systems are connected to reservoirs that can be easily refilled or switched to accommodate different coating materials. The dispensing unit is mounted on a movable arm that can traverse the length of the coating chamber, ensuring complete coverage of all tablets.

4. Adjustable Tablet Holder (104):
To accommodate different sizes and shapes of tablets, the system includes an adjustable tablet holder that securely holds the tablets in place during the coating process.

Design and Function:
- Adjustability: The holder can be adjusted vertically and horizontally to align with the spray nozzles. It can also rotate to ensure even coverage on all sides of the tablets.
- Modular Design: The tablet holder can be easily replaced with different modules to fit specific tablet shapes, such as round, oval, or oblong.
- Automated Adjustment: The microprocessor can adjust the holder's position based on pre-set configurations for different tablet sizes.

5. Reusable Powder Collection System (105):
This invention is the assimilation of a reusable powder collection system, which captures and recirculates excess powder during the coating process.

How it Works:
Collection Mechanism: The system includes a vacuum-based collector positioned below the coating chamber. Unused powder that does not adhere to the tablets is collected through suction.
Filtration Unit: The collected powder passes through a filtration system to remove impurities before being recirculated.
Powder Recycling: The filtered powder is stored in a secondary reservoir and fed back into the coating mechanism. This reduces raw material costs and environmental impact.

6. Integrated Infrared (IR) Drying System (106):
The invention integrates an infrared (IR) drying system to speed up the drying process between coating layers, ensuring that each layer adheres properly before the next one is applied.

Drying Process:
- IR Emitters: Positioned around the coating chamber, the IR emitters provide uniform heat distribution to the tablets.
- Temperature Control: The microprocessor 101 monitors the surface temperature of the tablets and adjusts the IR intensity to prevent overheating or damage.
- Energy Efficiency: The system is designed to conserve energy by activating the IR emitters only during the drying phase of the cycle.

7. Scalability and Modular Design (107):
The system is designed with a modular structure, making it highly scalable for both small batch production and large-scale manufacturing.

Scalability Features:
Modular Units: Each module, such as the coating chamber, drying unit, and powder collection system, can be expanded or replaced independently.
Batch Size Flexibility: The system can process anywhere from a few tablets to thousands, simply by adding or removing modules.
Easy Upgrades: New modules with enhanced capabilities can be integrated into the existing system without significant downtime.

8. Energy-Efficient Operation 108:
To address environmental concerns and reduce operational costs, the system includes several energy-efficient components.

Efficiency Enhancements:
Smart Power Management: The microprocessor 101 adjusts the power usage of various components based on real-time demand, such as reducing energy to the IR dryers during idle periods.
Low-Power Sensors: All sensors used in the system are optimized for low power consumption, reducing the overall energy footprint.
Standby Mode: The system automatically switches to a low-power standby mode when not in use.

Method of Performing the Invention:
Step 1: Preparation and System Setup:
1. Powering the System On:
- Turn on the main control unit 101. The microprocessor initializes the system, checks all connected sensors, and performs a diagnostic self-check.
- The user interface 109 displays system status and indicates if any components require maintenance before starting the process.

2. Loading Tablets:
- Place the tablets into the adjustable tablet holder 104. Adjust the holder as needed to accommodate the specific size and shape of the tablets.
- Secure the holder to prevent movement during the coating process, ensuring even coverage on all sides.

3. Configuring Parameters:
Use the control panel to set the coating parameters, such as:
- Coating thickness for each layer.
- Duration of powder and liquid application.
- Temperature settings for the integrated IR drying system 106.
- Spray interval timings for the intermittent coating mechanism 102.
- Load pre-configured settings if available for commonly used tablet formulations to reduce setup time.

Step 2: Initiating the Coating Process
1. Pre-coating Calibration:
The microprocessor 101 automatically calibrates the spray nozzles to ensure they are aligned with the tablets.
The system performs a pressure and flow rate check on the powder and liquid dispensers to avoid clogs and inconsistencies.

2. Starting the Coating Cycle:
Press the start button on the user interface 109 to begin the automated coating cycle.
The system initiates the intermittent coating mechanism 102:
- A layer of powder is applied to the tablets using the powder spray nozzle.
- After a brief pause, the liquid spray nozzle applies a thin layer of binder solution.

Step 3: Automated Coating Process
1. Powder and Liquid Application:
- The microprocessor controls the switching between powder and liquid sprays to achieve the desired coating layers.
- Sensors monitor the application in real-time to adjust the spray pattern and duration, ensuring uniform coating.

2. Drying Each Layer:
- Once a powder-liquid cycle is complete, the integrated infrared (IR) drying system 106 activates.
- The microprocessor adjusts the IR emitter's intensity based on real-time feedback from temperature sensors to avoid overheating.

3. Real-Time Adjustments:
- The optical sensors continuously check the thickness and uniformity of each coating layer.
- If deviations are detected, the system dynamically adjusts spray pressure, duration, or drying time to correct the issue.

Step 4: Recycling and Efficiency Measures
1. Powder Collection and Recirculation:
Excess powder that does not adhere to the tablets is collected by the reusable powder collection system 105.
The collected powder is filtered to remove contaminants and recirculated into the powder reservoir, reducing material waste.

2. Energy Efficiency:
- The system is designed to operate in an energy-efficient manner:
- The microprocessor 101 automatically switches components to a low-power mode during idle periods.
- The IR drying system 106 is activated only when needed, conserving energy.

Step 5: Completion and Quality Control
1. Final Coating Verification:
- Once the coating cycle is complete, the system performs a final quality check using the optical sensors to ensure that all tablets meet the specified coating thickness and uniformity.
- Tablets that do not meet the quality criteria are automatically flagged for re-coating.

2. System Shutdown:
- After the batch is completed, the microprocessor runs a final diagnostic check.
- The system enters standby mode, reducing power consumption while remaining ready for the next batch.

3. Cleaning and Maintenance:
- Detach the tablet holder 104 and clean it to remove any residual powder or coating material.
- Use the self-cleaning function for the spray nozzles to prevent clogging and ensure consistent performance in future batches.

Step 6: Optimal Performance
Regular Calibration: Ensure that the system is calibrated before each batch to maintain consistent quality.
Preventative Maintenance: Perform regular maintenance on critical components, such as spray nozzles and sensors, to avoid unexpected downtime.
Using Pre-configured Profiles: For commonly coated formulations, use pre-configured settings on the microprocessor to reduce preparation time and enhance reproducibility.
Batch Testing: Conduct a test run with a small batch of tablets before scaling up to full production to verify the coating parameters.
, Claims:1. A reusable powder-liquid intermittent coating system for pharmaceutical tablets, comprising:
? an automated control unit 101 integrated with a microprocessor for regulating the intermittent coating cycles;
? a powder and liquid coating mechanism 102 for alternating applications;
? multi-layer capability 103 for controlled drug release;
? an adjustable tablet holder 104 for various shapes;
? a reusable powder collection unit 105;
? an integrated IR drying system 106;
? modular design 107 for scalability;
? an energy-efficient components 108 to minimize power consumption.
2. A method for applying reusable and intermittent coatings to pharmaceutical tablets as claimed in claim 1, comprising the steps of:
? loading tablets into an adjustable holder 104;
? alternating between powder and liquid applications using an intermittent coating mechanism 102;
? using a microprocessor 101 to control timing and pressure settings;
? applying multi-layer coatings 103 with functional properties;
? employing an integrated drying system 106 between cycles; and
? recirculating excess powder using a reusable collection system 105.
3. The system as claimed in claim 1, wherein the intermittent coating mechanism 102 is configured to alternate between powder and liquid layers based on pre-set intervals controlled by the microprocessor 101 to optimise coating uniformity.
4. The system as claimed in claim 1, wherein the multi-layer coating capability 103 allows for the includes of active pharmaceutical ingredients, flavoring agents, or colorants within the powder and liquid layers to achieve functional coatings.
5. The system as claimed in claim 1, further comprising an integrated drying system 106 utilizing infrared (IR) technology to rapidly dry each coating layer between cycles, thereby reducing overall processing time.
6. The system as claimed in claim 1, wherein the adjustable tablet holder 104 is designed to rotate tablets during the coating process to ensure even coverage on all sides.
7. The system as claimed in claim 1, wherein the reusable powder collection system 105 includes a filtration mechanism to capture excess powder and recirculate it without contamination.
8. The system as claimed in claim 1, wherein the microprocessor 101 is programmed to adjust the spray pressure and nozzle position dynamically based on real-time feedback from optical sensors, ensuring consistent coating thickness across different batches.
9. The system as claimed in claim 1, further including a user interface that allows operators to set and modify coating parameters, such as spray duration, pressure, and drying time, according to the tablet formulation.
10. The system as claimed in claim 1, wherein the energy-efficient components 108 reduce power consumption by adjusting the energy supply based on the load requirements during intermittent coating cycles.

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