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      Pharmaceutical OSD and API

      Equipment for Pharmaceutical Manufacturing

      The definitive guide to selecting the right materials handling solution for OSD and API pharmaceutical manufacture, including best practice advice on feeding powders to roller compaction, tablet compression, capsule filling, tablet handling and what the ideal manufacturing plant would look like.

      30 Min Read Time

      Contents

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      What are the Biggest Challenges in Pharmaceutical Manufacturing?

      Pharmaceutical manufacturing is a highly competitive industry governed by strict regulations.

      To succeed, manufacturers need to match efficient throughput with careful materials handling, delivering products to a fast-paced market at the right price point. Any compromise on throughput or product quality can have serious consequences including failed batches, regulatory action or costly production stoppages.

      Whether manufacturers are handling oral solid dosages (OSD) or solvent-rich 'wet cake' solids (API), getting the materials handling system right is critical. Bottlenecks, slow throughput, tablet damage, product inconsistencies, and inefficient processes are common in this space.  The right equipment and plant design can address these issues systematically.

      Discover how we resolved powder segregation issues for one pharmaceutical manufacturer via the button below.

      Resolving Powder Segregation

      PHARMACEUTICAL MANUFACTURING EQUIPMENT

      Equipment Choices for Pharmaceutical Manufacture

      Each pharmaceutical manufacturing process will be determined by the powder characteristics.

      Problems can typically be traced back to inadequate or unsuitable equipment, or errors caused by manual intervention or operations. These can lead to mix segregation issues, lack of containment, or reduced powder flow from a container. In worst-case scenarios, production may stop entirely while the problem is fixed.

      Typically, there are two key areas where the feeding of powders to a processing step can cause issues:

      1. Feeding Powder to Direct Compression

      Although this is the quickest and most straightforward process for creating tablets, the following issues often occur:

      • Segregation of ingredients is a significant concern when feeding to direct compression, as it affects the uniformity of the finished tablet and risks the expense of failed batches.
      • Poor powder flow to the compression hopper at the correct rate results in a slower process, restricting factory capacity and throughput. 

      2. Feeding Granulated Material to Compression

      The two most common methods of tablet manufacture are via wet granulation or roll compaction. The wide-scale use of butterfly valves, implies that the material is expected to be 'free-flowing'. However, butterfly valves do run the risk of powder segregation and lack of powder flow control, which can lead to poor tablet quality, inconsistent dosing and increased batch rejection rates.

      ICON-pharma-PH-Wet-Granulation-grey-01

      Wet Granulation and IBC integration

      Matcon can save time by introducing IBCs before the mixing stage to feed powder to the high shear mixer. This reduces the preparation time before production begins. The IBC is filled in a separate dispensary and then brought to the granulation suite when needed. Controlled flow discharge from the IBC can be matched to suit the mixing capacity. 

      To learn more about milling equipment for wet granulation that integrates with Matcon powder handling systems, visit the Quadro website via the button below.

      Quadro Mills

      Dry Granulation

      Feeding to Roller Compaction with an IBC

      Inconsistent feed to the roller compactor can influence the finished product through variations in material density at the inlet, caused either by poor flow or by inconsistent “lumps” of product entering the inlet. Maintaining a consistent, controlled feed rate is essential for protecting batch quality and reducing the risk of costly rework.

      To learn more about roll compaction equipment for pharmaceuticals that integrates with Matcon powder handling systems, visit the Fitzpatrick website via the button below.

      Fitzpatrick Roll Compactors

      Solutions to Common Pharmaceutical Powder Handling Problems

      How Do You Blend Different Batch Sizes Using the Same Blender?

      When designing a new pharmaceutical plant or extension, blending method is a key consideration.

      Careful thought needs to cover all eventualities of batch size. How are you accommodating your smallest batch and your largest batch? Without proper planning, you could end up needing to buy 3 or 4 blenders, each of which will need its own dedicated space within your facility.

      Failing to get a balance between the size and number of blenders could mean increased quality control checks and added cost.

      Read our guide to blending different batch sizes using the same pharmaceutical mixing equipment

      How Do You Accurately Control Free-flowing Powders in Pharmaceutical Equipment?

      Does your mill or sifter run dry? Or is your pharmaceutical equipment being flooded by material? This is a clear sign that powder flow control needs attention.

      Many companies understand the advantages of using an IBC system, yet continue to use conventional butterfly or slide-valve IBCs. This does work well for some companies, but for others who have particularly challenging powder blends that are difficult to handle, the performance achieved can be disappointing. The cost of a failed or recalled batch can be substantial. 

      Explore discharge valve choices and how to control free-flowing powders in your pharmaceutical equipment.

      How Can Pharmaceutical Manufacturers Prevent Powder Segregation?

      Segregation of powders can lead to spoilt product and wasted materials. Equipment selection has a significant impact on eliminating powder control issues.

      As you investigate which IBC is the best option, do not be driven by price alone. What initially looks cheaper may not give you the performance you ultimately need. It is worth doing your research and understanding the benefits and limitations of the different types of IBC available. 

      Choosing the right type of IBC for your business depends upon a number of factors particularly if you have a product that is prone to segregation. Learn more about key equipment considerations for preventing powder segregation. 

      How Can Pharmaceutical Manufacturers Avoid Bin Rash?

      Hammer-rash or Bin-rash is the term used to describe the hammer pattern left when operators bang the side of the IBC bin to dislodge powders that have no't discharged properly.

      In addition to Bin-rash, it is not uncommon to see operators fully clothed in hazard suits manually rodding product out through the container inlet to clear a blockage.

      These issues can be avoided  entirely when you have the right powder flow system in place. They are also a significant GMP risk, as manual intervention introduces contamination potential and makes it impossible to guarantee batch integrity .

      Find out how to get better powder flow with Cone Valve technology.

      How Do You Avoid Powder Bridging in Manufacturing?

      All facilities that handle powders will have experienced cohesive or difficult powders at some point.

      These common issues often require operator intervention, such as ‘rodding’ or ‘hammering’. But valuable time is lost, and this does damage to the powder and equipment, not to mention the GMP risks involved.

      It is not accurately known how much valuable powder ingredient is lost each year, simply due to the loss of blend uniformity from manual intervention during the manufacturing cycle. 

      These costly issues can be reduced by selecting the right powder handling system. The Matcon Cone Valve IBC is designed so that, upon discharge, all the material in the container moves at the same rate across the whole container, creating uniform flow with no stagnant material, no rat-holing and a first in-first out sequence of material movement.

      Read our blog on avoiding powder segregation & bridging to find the Matcon solution that will reduce your cost per kilo.

      IBC Systems for Manufacturing Pharmaceuticals

      Matcon has worked with both OSD and API pharmaceutical manufacturers across the globe and has proven experience providing material handling solutions that meet the demands of heavily regulated production environments.

      Technology alone is not enough. At Matcon, we do not simply build and supply powder handling systems. We take the time to understand your business needs and design systems to meet those objectives. We have the facility to carry out comprehensive engineering studies and full-scale testing, which is vital in reducing the risk of new machinery investments and ensuring the system performs as expected before it reaches your facility.

      Resolving Powder Segregation

      IBC-Group-1
      RECOMMENDATIONS

      Why Choose a Matcon System for Pharmaceuticals

      One of the best solutions for feeding powders or granules to a downstream process is an IBC. But not all IBCs are built the same way, it is important to know what to look for.

      What initially looks like a cheaper option is usually cheaper for a reason and may not deliver the performance you need in practice. It is worth taking the time to research the benefits and limitations of different types of IBC. The key difference between systems lies in the outlet valve itself. Some manufacturers opt for IBCs fitted with a butterfly valve, while others supply IBCs with cone valves.

      Compared to butterfly valve IBCs, the Matcon Cone Valve IBC provides superior discharge control, preventing the traditional powder handling problems of powder bridging, rat-holing and blend segregation. For pharmaceutical manufacturers where batch quality and regulatory compliance are non-negotiable, this difference become significant. 

      Learn more about IBC discharge valves and how the Cone Valve suits pharmaceutical manufacturing.

      THE OPPORTUNITY

      Why are IBCs particularly suited to Pharmaceutical Manufacturing?

      IBCs offer several clear advantages over manual materials handling methods such as boxes, tubs or drums:

      Dust tight containment: Unlike open manual materials handling, IBCs are dust-tight, eliminating the potential for contamination and protecting operators and product integrity.

      Complete discharge: Cone Valve technology enables complete discharge of all materials from the IBC, leaving no residue or wasted product inside the container.

      Removed Bottlenecks: Using IBCs to move materials between processes removes bottlenecks, allowing each process to operate at its optimum rate and increasing efficiency and capacity.

      Parallel processing: With IBCs, it is much easier to feed the outputs of one common process into multiple lines so multiple products can be processed at the same time.

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      PHARMACEUTICAL OSD POWDER HANDLING

      Powder Handling Solutions for Pharma Solid Dosage

      Matcon offers a complete range of IBC solutions to pharmaceutical manufacturers worldwide.

      In the fast-evolving landscape of pharmaceutical manufacturing, achieving consistent quality, safety, and operational efficiency is essential, especially when handling powders and tablets for solid dosage forms. Matcon’s Cone Valve IBCs provide a reliable way to feed powders and granules into tablet compression or roller compaction, preventing segregation and delivering consistent product feed rates, while streamlining changeovers and ensuring regulatory compliance.

      The modular nature of a Matcon IBC system also means your facility can grow and adapt over time without requiring a complete overhaul of your production line. This flexibility supports both current operational needs and long-term capacity planning. 

      View Our Resource

      Pharma-Powder-Blending
      PHARMACEUTICAL BLENDING

      Blending Solutions for Pharmaceuticals

      Eliminate the time-consuming cleaning associated with traditional static mixers and improve your blending efficiency with just one blender.

      Achieving blend uniformity, product quality and efficient production is vital in pharmaceutical manufacturing, yet traditional static mixers often create bottlenecks and cleaning delays. Matcon’s IBC blending solutions transform this process, enabling rapid batch turnaround, reducing cleaning downtime, and ensuring regulatory compliance.

      Because the blend takes place inside the IBC itself, the blender never comes into direct contact with the product. This means cleaning between batches is minimal and completed off-line, and the risk of cross-contamination between different formulations is significantly reduced. The result is more productive shifts, better use of operator time, and consistent product quality across every batch. 

      Discover how innovative blending technology can support consistent product quality while driving operational excellence.

      View Our Resource

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      PHARMACEUTICAL TABLET HANDLING

      IBC Solutions for Tablet Handling

      Gentle handling of tablets in bulk using polyethylene tablet IBCs.

      Handling pharmaceutical tablets presents unique challenges, from minimising breakage and limiting contamination risk to ensuring efficient movement between process stages. Matcon’s modular IBC systems are designed to deliver gentle, contained transfer and storage of tablets, preserving product integrity, supporting compliance, and streamlining operations from production to packing.

      Accommodating a single coating batch in one tablet IBC, delivers production efficiencies through reduced manual handling, fewer repeated operations and less downtime. With decades of industry expertise, Matcon enables manufacturers to protect quality and maintain optimal throughput in modern facilities.

      View Our Resource

      pharma-api-powder
      POWDER HANDLING FOR API

      IBC Solutions for API Manufacturing

      Matcon’s Cone Valve Technology ensures a complete and controlled discharge of solvent-rich ‘wet cake’ solids.

      Cone Valve Technology allows efficient discharge of solvent-rich ‘wet cake’ solids, making Matcon Cone Valve IBCs ideal for transferring materials between centrifuges and dryers. This process control supports flexible manufacturing and improves efficiency across milling, sieving, and packing operations.

      Level probes or weight signals are used to ensure consistent feeding, helping to prevent overfeeding or interruptions during production. Whether you are upgrading an existing facility or building a new one, it is vital to consider how materials handling will affect your plant’s overall performance from the outset.

      View Our Resource

      RESOURCES FOR PHARMACEUTICAL MANUFACTURERS

      How IBC Cone Valve Technology Solves Pharmaceutical Powder Handling Problems

      Bridging, rat-holing, and blend segregation are terms that most pharmaceutical manufacturers know all too well. These problems slow production, waste product, and create compliance risks that are difficult to manage at scale.

      Matcon Cone Valve IBC technology addresses all three powder problems. The Cone Valve is designed so that upon discharge, all the material in the container moves at the same rate across the whole container. This creates uniform mass flow with no stagnant material, no rat-holing, and a first-in, first-out sequence of material movement. The result is consistent blend quality, less waste, and fewer operator interventions during production 

      Learn more about Matcon Cone Valve technology and how Cone Valves are the optimum solution for manufacturers processing anything from cohesive to free-flowing powders.

      Learn About IBC Cone Valve Technology
      Cone valve technology brochure
      RESOURCES

      Better Ways of Handling Tablets Using IBCs

      If you can accommodate a single coating batch in one IBC you will naturally see production efficiencies through reduced manual handling, fewer fewer repeated operations and less downtime.

      This is just one way in which IBCs can improve the way in which you handle tablet manufacture, download our guide to discover more.

      Discover Better Ways To Handle Tablets Using IBCs
      better ways to handle tablets brochure
      MANUFACTURING PLANT DESIGN

      Is Your Pharmaceutical Manufacturing Plant Designed for Best Results?

      Selecting the right materials handling equipment for OSD and API manufacture is only part of the process. Careful thought should be given to the layout of your manufacturing plant if you are to achieve the throughput and quality levels required in this industry.

      Where Do You Start When Designing a Pharmaceutical OSD Facility?

      If you are designing a new facility or adapting an existing space, it is vital to think through each step involved in production:

      • Do you blend ingredients, press tablets, carry out quality control procedures or package products in different ways?
      • What equipment do you need at each process step, and how much space does it require?
      • How do you move materials between the different steps in the production process?
      • How do you  decide the most efficient location of internal Zoning areas and product flow to external logistics?

      Getting clear answers to these questions early in the design process will save significant time, cost, and disruption later.

      How Does Facility Layout Affect Equipment Choices?

      How you configure your production area directly influences what equipment you choose and how the manufacturing process flows. Pharmaceutical production facilities typically fall into three categories:

      1. Single-floor facilities
      2. Two-floor facilities
      3. Multiple floor facilities

      Each has its own advantages and disadvantages depending on your product range, batch sizes, regulatory requirements, and available space.  Read our guide to designing a Pharmaceutical Manufacturing Facility to understand which layout suits your needs, or explore how to use IBCs in a two-floor pharmaceutical facility for a practical breakdown.

      Why Does Materials Handling Matter in Plant Design?

      Not thinking carefully about how powders, granules, tablets, and capsules are handled and moved from one stage of the production process to another can create inefficiencies that seriously limit capacity and the ability to grow over time.

      The most traditionally used method to move materials is manually via tubs, drums, or boxes.  This can, however, lead to wasted product, lost time, increased energy use and ultimately a quality control issue. One way to remove the handling problem is to couple all processes together, which cuts waste but makes the whole line dependent on the speed of the slowest step.

      The most effective solution is to use Intermediate Bulk Containers (IBCs) to move materials between processes. IBCs decouple each stage of production, allowing every process to run at its optimum rate independently, without one step holding back the rest of the line. 

      Single Floor Facility diagram
      Single-floor facility
      Two Floor Facility diagram
      Two-floor facility
      Multiple Floor Facility diagram
      Multi-floor facility
      RESOURCES

      A Guide to Designing the Ideal Pharmaceutical Manufacturing Plant

      Discover how a change in the way materials are handled can give manufacturers of pharmaceutical oral solid dosage (OSD) products an ‘edge’ over their competitors. Assembling a factory is not simply a question of ‘fitting it all in’ read the guide to learn how the design of a pharmaceutical manufacturing plant brings efficiencies and a competitive advantage to your business.

      Complete with factory layouts and insights on how to avoid common process flow problems, this is a must have guide for anyone consider an operational change to their pharmaceutical manufacturing facility.

      Ideal Design of a Pharmaceutical Manufacturing Plant
      Better buildings for pharmaceutical production brochure
      RESOURCE

      How to Select the Right Pharmaceutical IBC Supplier

      Choosing the right IBC system to meet your pharmaceutical needs can be difficult. Get it wrong and you potentially face many of the powder handling issues discussed.

      To help you ask the right questions of your IBC provider, Matcon has developed the Ideal IBC System Checklist.  This resource helps you validate your equipment procurement process and ensure the IBC meets all your needs before you commit to a purchase. Taking the time to work through this checklist can protect your investment and prevent costly problems further down the line..

      Guide to Selecting the Ideal IBC Supplier
      Selecting the ideal pharmaceutical ibc supplier checklist
      THE OPPORTUNITY

      Engineering Resources for Pharmaceutical Powder Handling

      Access Matcon's detailed engineering resources to help guide you to Pharmaceutical Powder and Tablet Handling Best Practice. These resources are designed for the pharmaceutical industry to support Engineering Managers in increasing production efficiency using the unique features of the Matcon IBC Cone Valve.

      Whether you are evaluating new equipment, planning a facility upgrade, or looking to resolve a specific powder handling challenge, our engineering documentation provides practical, technical guidance based on real-world pharmaceutical manufacturing experience.

      PHARMACEUTICAL RESOURCES

      IBCs for OSD Pharmaceutical Production

      Learn how to handle your powders and tablets more efficiently with a Matcon Cone Valve IBC, enabling you to reduce powder segregation, increase productivity and product yield.

      IBC Solutions for Solid Dosage
      IBC solutions for solid dosage brochure
      GET IN TOUCH

      Is Your Pharmaceutical Plant Achieving the Best Results?

      If you have a powder handling issue or want help specifying the right equipment for Pharmaceutical Manufacturing, contact us to speak to one of our powder handling specialists. 

      The Original Cone Valve IBC Manufacturers

      At the heart of the Matcon system you will find the Cone Valve - invented, patented and developed by us. We help manufacturers overcome issues of mix segregation, containment and bridging that are inherent in traditional powder handling systems. Discover our unique approach to powder handling and the innovation that underpins all that we do.

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