ODF Coating Challenges for High-Viscosity and High-Load Formulations
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Introduction
With the rise of oral dissolvable films (ODFs) in both pharmaceutical and functional food sectors, the demand for high-dose, multi-ingredient formulations is growing rapidly. From nutrient-dense vitamin films to drug-loaded therapeutic films, one key question emerges: how can companies maintain dose uniformity while stably coating high-viscosity materials?
1. Technical Barriers in High-Viscosity Coating
- Poor flowability: Thick formulations can lead to uneven coating when traditional methods are used.
- Drying inefficiency: High solid content slows down water evaporation, increasing the risk of residual moisture.
- Dose uniformity risks: High load concentrations make batch-to-batch consistency more difficult to control.
2. Common Industry Pain Points
- Slot-die coating struggles with high-viscosity materials, causing nozzle clogging and poor layer uniformity.
- Drying speed vs. energy usage: high heat may degrade temperature-sensitive actives.
- Scaling up from lab to production often leads to significant formulation and performance deviations.
3. HUANGHAI’s Solution
- Patented Scraper Coating Technology: Adjustable micro-gap scraper ensures consistent spread of thick formulations.
- Gradient Hot-Air Drying: Optimized airflow design boosts drying efficiency while protecting active ingredients.
- Scalable Equipment Portfolio: MJ150-L for lab/pilot scale; MJ150 for high-volume commercial production.
4. Regulatory & Quality Value
- Meets dose uniformity and dissolution standards under Chinese Pharmacopeia, USP, and EP.
- Stable process reduces batch variation, facilitating registration and export compliance.
- Ensures high-performance membranes across nutraceutical and pharmaceutical segments.
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Conclusion
High-viscosity and high-load formulations represent a promising future for ODF development, but they demand more sophisticated coating strategies. With our scraper-based coating and energy-efficient drying systems, HUANGHAI delivers robust, scalable solutions to help you transition from lab to launch with confidence.