Innovation in continuous coating for the pharmaceutical industry.

Introduction

Thomas Processing has been a pioneer in continuous tablet coating since 1993. The ACCELA CTC 1000 represents the latest advancement in this field, engineered to handle high-volume production ranging from 200 to 1,200 kg/h in a true continuous process.
The CTC design eliminates material waste and reprocessing during startup and shutdown, addressing key inefficiencies found in other coating systems. In addition, the Thomas ACCELA CTC 500 and CTC 1000 are the only continuous coaters on the market built with an integrated curing chamber, which streamlines the process flow and eliminates the need for external equipment.
In this article, Alessandro Paolini, Sales & Marketing Director at IMA Thomas, explains the technical features, operational benefits, and production integration of the ACCELA CTC 1000. He also highlights how IMA Thomas Competence Center supports pharmaceutical manufacturers in successfully transitioning from batch to continuous coating.

What design features help protect the tablets and ensure product continuity?

The ACCELA CTC’s shallow bed depth ensures gentle tablet handling, preserving sharp edges and clear logos. A short residence time, typically 10 to 15 minutes, minimises heat and mechanical stress. The integrated curing chamber allows the film to fully set before discharge no additional equipment is required. Together, these features maintain product quality, even at high throughput, and support consistent, reliable coating performance from start to finish.

How does the spray gun operation support processing and tablet quality?

During ACCELA CTC startup, spray guns are activated one zone at a time, under fully automated recipe control. The result is uniform coating from the first tablet to the last, with no product loss during startup or shutdown.

How does the ACCELA CTC 1000 integrate with IMA Thomas Competence Center to support customers scaling from R&D to full production and ensure quality?

We begin by reviewing our customers’ existing batch processes and their critical parameters. Using our TAAC film coating modeling tool, we translate those conditions into the CTC environment. Trials are run at the Competence Center using the customer’s own tablets and formulation. This hands on approach ensures a smooth, predictable transition to full-scale production, while maintaining critical quality attributes and minimising development risk.

How does the ACCELA CTC 1000 integrate with tablet presses to create a complete oral solid dosage solution, and how does the Competence Center facilitate this?

In the field, we can integrate the ACCELA CTC 1000 with an IMA tablet press to form a full process system. We implement a handling process between machines to balance product flow, ensuring smooth and coordinated production. IMA MAESTRO software supervises the machines, managing quality and generating batch reports.
Ahead of implementation, we use the Competence Center to define control logic and simulate the interface. So, customers can implement a harmonised, end-to-end solution with confidence, even if press and coater aren’t yet connected on-site.

How does the IMA Thomas Competence Center help customers transition from batch to continuous coating processes?

At the Competence Center, we can replicate batch processes using batch coaters in our own lab. Starting from the customer’s parameters, we recreate the process and then use the TAAC modeling tool to transfer them to continuous coating technology. With a continuous coater available in our Competence Center, we physically demonstrate the technology transfer, enabling a smoother transition.

Looking ahead, how do you see IMA continuing to innovate and provide solutions in the oral solid dosage market?

IMA Thomas doesn’t just react to market needs but anticipates them by developing new technologies, automation approaches, and solutions. Our innovation is shaped by real customer challenges especially those we solve through trials at the Competence Center. Our goal is to help customers achieve greater efficiency, higher productivity, and more flexible production, always with an eye on quality, reliability, and ease of use for production teams.