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International clients
Tabletting specialists

Accelerating Tablet Development

A leading pharmaceutical company was encountering issues when attempting to scale up a new immediate-release tablet formulation. During early trials, the formulation scientists encountered several compression challenges such as capping, lamination and inconsistent hardnesses, which prevented them from achieving the target tablet quality.

Their in-house resources were already stretched, and limited quantities of active material meant traditional large-scale trails were impractical. The client required quantitative, small-sample data to understand the root causes and guide formulation adjustments before proceeding further.

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Solution

The client approached us for a bespoke compaction programme tailored to their specific formulation.

We designed a targeted study using only 20g blends. We used our Tubular T2 blender to prepare a range of prototype blends.

By combining tabletability, compressibility and ejection data, we identified which formulation variables most strongly influenced tablet strength and defect rate.

Our Case Study Highlights:

  • Using small amount of material to generate quantitative data, enabling rapid formulation optimisation.
  • Combined tabletability, compressibility and ejection force data to pinpoint the key variables.
  • Delivered clear recommendations on blend modifications, lubricant levels and optimal compression settings.
  • Providing tabletability curves and expert guidence, allowing the client to move forward confidently with a product.

Results

Merlin delivered a comprehensive report that indicated:

  • The optimal compression parameters for robust tablet formulation
  • A direct relationship between lubricant concentration and ejection force
  • A recommended blend modification that improved tablet strength
  • Predictive tabletability curves for future scale-up validation

These insights allowed the client to optimise their formulation and take a low risk approach to eliminate the original capping issue.

By combining advanced compaction technology with deep expertise in powder behaviour, Merlin helped the client transform an uncertain formulation into a manufacturable product saving both time and material in the process.

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