Tablet dosage forms remain one of the most widely used drug delivery systems due to their convenience, stability, and cost-effectiveness. However, the manufacturing of tablets is often challenged by a range of processing problems that can compromise product quality, efficacy, and patient compliance. Common issues include capping, lamination, sticking, picking, mottling, weight variation, hardness inconsistency, and friability. These problems arise from multiple factors such as poor powder flow, inadequate granulation, improper compression force, or unsuitable excipient selection. Environmental conditions like humidity and temperature further exacerbate these defects. Remedies involve a systematic approach that integrates formulation optimization, process control, and equipment calibration. For instance, capping and lamination can be minimized by adjusting compression force, improving binder concentration, or modifying punch design. Sticking and picking are often resolved by using anti-adherent agents, polishing punches, or controlling moisture content. Weight variation and hardness issues demand uniform granulation and precise machine settings, while mottling can be corrected through proper mixing and use of stable colorants. Advances in process analytical technology (PAT), direct compression techniques, and continuous manufacturing have further enhanced the ability to monitor and control these challenges in real time. Ultimately, successful tablet production requires a holistic understanding of material science, process engineering, and quality assurance. This review highlights the major tablet processing problems, their root causes, and practical remedies, offering insights for pharmaceutical scientists and manufacturers to achieve consistent, high-quality tablet formulations.
*Asma Tabassum, Komire Pavyasri, Bussa Srija, Vupparapally Pravalika (Mon,) studied this question.