The Revolutionary Auto Coater in Pharmaceutical Manufacturing
In the fast-paced world of pharmaceutical manufacturing, every second counts. That’s why advancements in tablet coating technology play a vital role in optimizing productivity and efficiency. One such revolutionary innovation is the Auto Coater, a game-changer in the industry.
The Auto Coater is a sophisticated automatic coating machine designed to coat tablets, pills, granules, and candies with a thin film coating, ensuring uniformity, precision, and superior quality. It eliminates human error while enhancing production speed, making it indispensable in the pharmaceutical and food industries.
The auto coater consists of a control system, a hot air filtering system, a coating pan, a solution tank, and an exhaust system. The film to be coated on the tablet is in liquid form before the process is started, so the liquid is filled in the solution tank. The liquid is stirred well in the solution tank and then pumped into the coating pan. The coating pan is perforated and holds a batch of tablets that are to be coated. A set of spray guns is present at the center to spray the coating liquid on the tablets. The coating pan can rotate on its axis.
Hot air is passed in from a hot air blower and then passed through a series of filters to remove impurities. The filters used are a washable filter, pre-filter, and HEPA filter. The air from the blower is not hot initially, so a steam heater is used to heat the air before passing it into the coating pan. The machine is operated by PLC controls from the control panel.
In the coating process, the tablets or similar products that are to be coated with film coating are filled into the coating pan. The coating liquid is pumped from the solution tank into the coating pan. The spray guns spray the tablets with atomized particles of
the coating solution as the perforated coating pan is rotated so that the entire batch of tablets is evenly coated. Simultaneously, the hot air from the blower is passed in to the drum at negative pressure which dries the sprayed coating evenly and rapidly which then causes it to become a solid and smooth surface film on each of the tablets.
The air is then exited from the perforated coating pan and moves to the exhaust system. The exhaust system consists of an exhaust blower to send the exit air from the coating pan to the external environment. The exhaust system consists of a dust collector which is also called a scrubber. In some systems, wet scrubbers are used to filter the particulates in the exhaust. The liquid droplets within the wet scrubber absorb the particulate matter thereby filtering the exhaust air before release.
Working Principle of the Auto Coater
The Auto Coater consists of several essential components, including:
- Control System (PLC-based for automation and monitoring)
- Hot Air Filtering System (includes washable filters, pre-filters, and HEPA filters)
- Coating Pan (Perforated Pan with larger openings for enhanced coating efficiency)
- Solution Tank (where the coating solution is prepared and stored)
- Exhaust System (Dust Collector / Scrubber for removing particulates)
- Spray Guns (High atomizing spray system for precise application)
- Hot Air Blower (assisted by a steam heater to optimize drying)
- Peristaltic Pump (for controlled transfer of coating liquid)
- Electric Motors (ensuring smooth pan rotation)
- Touch Screen Operation Panel (for user-friendly interface and control)
How the Auto Coater Works in Pharmaceutical Manufacturing
The process begins with filling the perforated coating pan with a batch of tablets. The coating solution is pumped from the solution tank to the spray guns, which atomize and spray the film coating evenly on the tablets. Meanwhile, hot filtered air passes through the coating pan under negative pressure, ensuring rapid drying and formation of a smooth and stable surface film on the tablets.
The exhaust system with a dust collector (scrubber) removes excess particles, ensuring a clean and controlled environment. In some setups, a wet scrubber is used to filter particulates from the exhaust air, enhancing environmental safety.
Comparison of Auto Coater with Traditional Coating Methods
Traditional tablet coating methods rely on manual labor, increasing the likelihood of inconsistencies. The Auto Coater offers several advantages:
- Increased Production Speed – Coats large batches efficiently compared to traditional small-batch coating.
- Superior Coating Uniformity – The high-tech spraying system ensures consistent film thickness.
- Reduced Human Error – Automation reduces manual intervention, improving quality control.
- Energy-Efficient Design – Minimizes steam and compressed air consumption, reducing operational costs.
- Flexible Batch Operations – Allows customizable pan speed, coating parameters, and process monitoring.
- Enhanced Drug Stability – Protects tablets from moisture, oxidation, and external contamination.
- User-Friendly Operation – Features an intuitive PLC-based touch-screen panel for precise control.
Applications of Auto Coater
The Auto Coater is widely used in pharmaceutical and food industries for various applications:
- Film Coating of Tablets (with aqueous coating, organic solvent coating, and enteric coating)
- Masking Unpleasant Taste of tablets
- Coating Granules, Capsules, and Sweets
- Sugar Coating in Candies
- Enhancing Drug Shelf Life
Installation & Safety Features
Installation:
- Proper power connections and air inlet/outlet setup are essential.
- Liquid to be coated is loaded into the solution tank, and the machine is switched on.
- Rotational speed, temperature, and pressure are adjusted via the control panel.
Safety Features:
- Overload Pressure Release Mechanism
- Emergency Stop Button
- Separate Production & Technical Areas
- Advanced Coating Pan Design to prevent tablet breakage
Specifications of Auto Coater
The Auto Coater comes with varying capacities, ranging from 30 kg per batch to 500 kg per batch. Other essential specifications include:
- Pan Diameter & Mouth Diameter
- Pan Speed & Main Drive Motor Capacity
- Inlet Air Blower Motor Power
- Steam Consumption & Compressed Air Requirement
Conclusion
The Auto Coater has transformed pharmaceutical manufacturing by offering high efficiency, precision, and automation in tablet coating. With its state-of-the-art technology, it has become the preferred choice for manufacturers aiming to increase productivity, maintain high-quality standards, and reduce operational costs. As the industry continues to evolve, the Auto Coater remains at the forefront, ensuring superior coating solutions for a safer and more efficient pharmaceutical production process.
For top-quality Auto Coaters, The Bombay Engineering Works is a trusted manufacturer in Mumbai, India, delivering cGMP-compliant, energy-efficient, and high-performance machines that meet the highest industry standards.