Surface Measurement Systems has demonstrated how Dynamic Vapor Sorption (DVS) can serve as a powerful Process Analytical Technology (PAT) tool for pharmaceutical manufacturers seeking to optimize tablet film coatings.

Film coatings are critical for moisture‑sensitive products, directly influencing drug stability, safety, and efficacy. Traditional methods such as Karl Fischer titration or long‑term storage studies often lack the sensitivity to detect subtle differences in coating quality. DVS, by contrast, provides real‑time, quantitative insight into moisture uptake, sorption kinetics, and diffusion behavior under controlled humidity and temperature conditions.

In a collaborative study with Colorcon, placebo tablets coated with Opadry AMB and Opadry AMB II were analyzed. Results showed that Opadry II consistently delivered superior moisture‑barrier performance, with lower equilibrium mass gains and reduced diffusion coefficients compared to Opadry AMB. Coating thickness and process conditions were also found to be decisive factors: thinner coatings produced higher moisture uptake, underscoring the importance of precise process control.

The findings highlight DVS as a sensitive, reliable PAT solution for monitoring coating integrity and guiding formulation design. By enabling manufacturers to correlate coating composition and thickness with functional performance, DVS supports the development of robust, moisture‑protected oral dosage forms.

For pharmaceutical companies, this means faster, more informed decisions during drug development — and ultimately, better protection for moisture‑sensitive active ingredients.

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