At Coating Place, we use a two phase approach in the formulation development process.
During the initial phase, we begin by assessing the product’s requirements and identifying the coating system that is best suited to the project. We consider all formulation alternatives during this phase to ensure an optimal final product. The factors examined include the form or derivative of the core material presented, particle size, cost parameters, and production requirements.
Before beginning the Wurster process, the desired properties of the product are defined to aid in determining the variety of coating materials to be used, the formulation of each coating if multiple layers are required, and the necessary processing parameters. If a complex application is require, other factors may be taken into consideration, including:
- Aqueous vs. Solvent-based Approaches
- Multiple vs. Single Layer Coating
- Multiple vs. Single-component Coatings
The final process determination may require analyzing results from numerous formulations as similar properties may be achieved. Our 40 years of experience across a wide range of Wurster applications proves invaluable to you and your team when choosing your final formulation process.
Once the formulation has been identified, coating experiments are conducted to study the release characteristics that can be achieved. The coating parameters used include layer thickness, process temperatures, spray rates, drying time, and solvent selection. To ensure an optimal final product, these parameters are studied over numerous batches and through multiple formulations. When studying the coated materials, testing may be conducted during the process in-suite or more extensively with our quality control laboratory. Success or failure of each formulation product is further used to optimize the process and develop a product for commercial manufacturing.