General Purpose Coatings


Instacoat 4G

Product Description

INSTACOATTM 4G is a ready-mixed powder that can be rapidly reconstituted in water, for the film coating of solid oral dosage forms. It contains polymer, plasticizer, pigments, etc. in optimal ratios to achieve significant benefits in terms of processability and product quality.

It is available in a wide range of shades to customer specifications.

Features Benefits


  • Dry powder system for reconstitution
  • Process time savings from rapid coating suspension manufacture
  • Complete coating formulation minus solvent
  • Cost savings in inventory and inventory management
  • Advanced colour control methods
  • Reproducible finished product appearance
  • Avoidance of customer complaints
  • White or ready coloured systems matched to your specification or sample are available. Anti-counterfeiting and branding features can be built-in
  • Meeting diverse marketing requirements is facilitated
  • Colours used are checked for compliance with appropriate regulations in target markets
  • Avoidance of regulatory issues


  • PVA is a low viscosity polymer
  • Coatings are smooth, glossy and resilient to physical damage. Packaging speeds are enhanced.
  • Solids levels up to 35% facilitate rapid coating thus major productivity gains.
  • PVA is highly water soluble
  • Rapid suspension preparation
  • Minimal impact on dissolution and disintegration.
  • Avoids use of expensive super-disintegrants in tablet core.
  • Aqueous processing promotes a safe working environment and avoidance of atmospheric pollution.
  • Anti-tack agent
  • Overcomes PVA tack issues and contributes to productivity gains.
  • PVA is a highly adhesive polymer & is supplemented by an adhesive enhancing agent.
  • Excellent logo definition and freedom from coating faults such as logo bridging despite high application rates.
  • Can be applied in a wide range of equipment designs and sizes from most manufacturers.
  • Easy scale-up and transfer to different equipment types or manufacturing sites.
  • Suitable for batch and continuous processes.
  • Single polymer and absence of soya lecithin.
  • Facilitates product registration in multiple regulatory environments.

Regulatory information

All products are checked for the regulatory compliance of all ingredients in the target countries and market segments of sale. This determination is made at the time the initial formulation is established, based on customer-supplied information. If market countries and/or segments are extended once the formulation has been established, customers are encouraged to contact us to ensure that regulatory compliance is not compromised.

Recommended Solvent System and Reconstitution Level

  • Purified water at up to 35% w/w solids

Equipment / Accessories

  • Variable-speed mechanical stirrer
  • Mixing Vessel

Calculation of InstacoatTM4G and solvent quantities

  • Determine the quantities of InstacoatTM 4G (35% w/w solids) and water required, based on the quantity of tablets to be coated and the target coating weight gain. e.g.: For coating 1.0 kg of tablets to 3% wt. gain, weigh 3 g Instacoat and 61.3 gm purified water at room temperature (includes 10% overage for losses).

Reconstitution Process

  • Add the weighed quantity of water to a mixing vessel.
  • Using a mechanical stirrer, stir the purified water to form a vortex.
  • Add required quantity of InstacoatTM 4G to the centre of the liquid vortex in a slow steady stream, avoiding clumping while maintaining a vortex. Once the entire quantity of Instacoat has been added, reduce the stirrer speed to eliminate the vortex. (Fig. 2) Continue mixing for 45 minutes.

Recommended Process Conditions

(fully perforated) pans
(non perforated) pans
Continuous Coaters
Pan diameter (inch) 24-60 12 24-30
Tablet load (kg) 10-350 0.5-1.0 150-430 static
Tablet throughput (kg/hr) N/A N/A 500-635
Weight gain (%) 2.5-3.0
Number of guns 1-6 1-2 14-22
Liquid nozzle diameter (mm) 1.0-1.2
Atomising air pressure (bar) 3.0-4.0
Pattern air pressure Set to achieve maximum uniform bed coverage
Tablet bed temperature (⁰C)* 42-46
Inlet air temperature (⁰C) Set to achieve required bed temperature & process time
Suspension spray rate (g/min) Set to achieve required bed temperature
Exhaust air volume To maintain slight negative pressure in pan
Pan speed To achieve steady tablet flow through spray zone

*Tablet bed temperature offers the most effective way of controlling the coating process. Where this measurement is unavailable, exhaust temperature may be substituted. However, the relationship between the two measurements is complex and depends on several factors such as pan load, pan depression, pan design and airflow rate. Indicated exhaust temperature may be above or below the true bed temperature. It is recommended that the relationship between the two measurements is calibrated.

Typical Constituents

PVA; Plasticiser; Titanium Dioxide; Edible Pigments, Anti-Tack & Adhesion Enhancing agents.