Simultaneous optimization of inter- and intra-tablet coating variability in a lab-scale coating process via DEM-MC simulations

This work presents a novel time-scale extrapolation method to predict the amount and location of the coating material on tablets based on short discrete element method (DEM) simulations. Using the proposed workflow, the coating amount can be determined on pre-defined surfaces of any tablets during the process time. Due to its swiftness, the workflow is well-suited for evaluating the effect of various process parameters on the coating quality. The current work examines the influence of process parameters (i.e., the filling mass, rotational speed, and spray rate) on the coating quality of single tablets in a lab-scale pan coater. The results show that the presented workflow allows us to successfully predict the coating quality of single tablets and the batch. Moreover, we established that there is no universal optimal process setting, and the purpose of coating should be considered in the course of any optimization effort.