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Tablet design with a focus on maximizing production efficiency – How it’s done at Adamus S.A.

Modern pharmaceutical manufacturing places increasingly high demands on tablet producers—not only in terms of the quality of the final product, but also regarding process efficiency, tool durability, downtime reduction, and compliance with strict regulations. A key to success lies in properly designed tablets—not only in terms of pharmaceutical formulation, but also geometry, surface finish, quality of markings, and the materials and coatings used.

In this field, Adamus S.A. has been standing out for years. As a manufacturer of precision tooling for tablet presses, Adamus supports clients at every stage— from design through production to servicing and operator training—offering a comprehensive approach.

The importance of proper tablet design

Tablet design should never be random—every detail matters in the compression process, tool wear, and final product quality. The shape of a tablet affects its flow properties and compressibility—tablets with simple, smooth shapes (round, oval) promote even force distribution during compression and reduce the risk of contamination and tool damage.

In contrast, complex shapes, sharp edges, or deep embossing can lead to the sticking of tablet mass to the punch surface and increase the likelihood of defects.

Graving or logos on the tablet surface also require precise planning. These elements must remain within the so-called “safe zone” to avoid rapid tool wear and reduced legibility of engravings/logos. Lines that are too thin, sharp angles in letters, or deeply set graphic elements may contribute to the phenomenon known as “picking”—the detachment of tablet particles, which leads to tool contamination and tablet defects.

Another important aspect is the application of protective coatings on tablets. Beyond aesthetic and taste-related functions, coatings protect the tablet from moisture, facilitate swallowing, and improve mechanical resistance during packaging.

It’s also worth noting that punches themselves are often covered with protective coatings. You can learn more about the types of coatings here: https://www.adamus.com.pl/en/punches-and-dies/rodzaje-powlok
We also recommend checking out our case study on punches with ADACON coating: https://www.adamus.com.pl/pl/component/content/category/15-case-study-main?Itemid=330

Adamus S.A.’s role in tablet production optimization

Operating since 1981, Adamus S.A. has earned recognition from pharmaceutical manufacturers worldwide. With its extensive experience and advanced technological capabilities, Adamus supports clients not only in selecting the right tools but also in optimizing the tablet design process itself. Adamus provides precision-made punches and dies tailored to the most demanding designs. The company can produce both standard and customized shapes, including tools for non-standard tablet forms.

By implementing Industry 4.0 solutions, Adamus has automated many stages of tool production—from polishing and measurement to ultrasonic cleaning and tool storage management. This ensures repeatable parameters, saves time, and significantly reduces the number of complaints and production line downtimes. A key part of the offering is training at the Adamus Academy, where participants gain knowledge in tool maintenance, troubleshooting common technological issues (such as lamination, picking, and capping), and recognizing tool wear.