an overview on bilayered tablet technology

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WORLD JOURNAL OF PHARMACY AND PHARMACEUTICAL SCIENCES
SJIF Impact Factor 2.786
Volume 4, Issue 04, 386-403.
Review Article
ISSN 2278 – 4357
AN OVERVIEW ON BILAYERED TABLET TECHNOLOGY
Chintan R Dhorajia*, Jaymin M Patel, Kaushika S Patel, Shreeraj Shah and
Pratik upadhyay
Department of Pharmaceutical Technology, L J Institute of Pharmacy, Ahmedabad- 382 210.
Article Received on
25 Jan 2015,
Revised on 18 Feb 2015,
Accepted on 14 March 2015
ABSTRACT
Over the past 30 years stated that the expense and complications
involved in market ing newdrug entities have increased, with
concomitant recognition of therapeutic advantages of controlled drug
delivery, greater attention has been focused on development of
*Correspondence for
sustained or controlled release drug delivery systems. Bilayer tablet is
Author
Chintan R Dhorajia
new era for the successful development of controlled release
Department of
formulation along with various features to provide a way of successful
Pharmaceutical
drug delivery system. Controlled release dosage forms have been
Technology, L J Institute
extensively used to improve therapy with several important drugs. Bi-
of Pharmacy, Ahmedabad-
layer tablet is suitable for sequential release of two drugs in
382 210.
combination, separate two incompatible substances and also for
sustained release tablet in which one Layer is immediate release as initial dose and
second layer is maintenance dose. Bilayer tablet is improved beneficial technology to
overcome the shortcoming of the single layered tablet.
KEYWORDS: Bilayer tablet, Bilayer tablet press, GMP requirements, OROS push pull
technology, DUROS technology.
INTRODUCTION[1,2]
Now a day’s various developed and developing countries are moving towards combination
therapy for treatment of various diseases and disorders requiring long term therapy such as
hypertension, Diabetes and Rheumatoid arthritics. The problem of dose dependent side
effects is minimized by combination therapies and is advantageous over monotherapy. From
last few years, interest in developing a combination of two or more active pharmaceutical
ingredients in a single dosage form has increased in pharmaceutical industry.[1]
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World Journal of Pharmacy and Pharmaceutical Sciences
Bi-layer tablets can be a primary option to avoid incompatibilities between APIS by physical
separation. Bi-layer tablet is suitable for sequential release of two drugs in combination,
separate two incompatible substances and also for sustained release tablet in which one layer
is immediate release as initial dose and second layer is maintenance dose.[1]
Bi-layer tablets are tablet, made by compressing two different granulations fed into a die
succession, one on top of another, in layers. Each layer comes from a separate feed frame
within individual weight control. Rotary tablet press can be setup for two layers. They have
the appearance of a sandwich because the edges of each layer are exposed. General concept
of bi-layer tablet is shown in figure.[2]
Fig.1 General Concept of bilayer tablet
Generally conventional dosage form produce wide ranging fluctuation in drug concentration
in the blood stream and tissues with undesirable toxicity and poor efficiency. This repetitive
dosing and unpredictable absorption led to concept of controlled drug delivery system.[2]
The goal in designing sustained or controlled delivery systems is to reduce frequency of
dosing or to increase effectiveness of the drug by localization at the site of action. Primary
objective of sustained release delivery is to insure safely and to improve efficacy of drugs as
well as patient compliance.[2]
1. Advantages

They are unit dosage form and offer the greatest capabilities of all oral dosage form for
the greatest dose precision and the least content variability.
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
Cost is lower compared to all other oral dosage form.

Lighter and compact.

Easiest and cheapest to package and strip.

Easy to swallowing with least tendency for hang-up.

Objectionable odour and bitter taste can be masked by coating technique.

Suitable for large scale production.

Greatest chemical and microbial stability over all oral dosage form.

Product identification is easy and rapid. Requiring no additional steps when employing an
embossed and/or monogrammed punch face.
2. Disadvantages

Bilayer rotary press is expensive.

Inaccurate individual layer weight control.

Some drugs resist compression into dense compact, due to amorphous nature, low density
nature.

Insufficient hardness, layer separation, reduced yield.
3. Types of bilayer tablet[3,4]
The term bilayer tablets containing subunits that may be either the same (homogeneous) or
different (heterogeneous).
3.1. Homogenous type
Fig.2 Bilayer tablets (same drug with different release pattern-homogenous)

Bilayer tablets are preferred when the release profiles of the drugs are different from one
another. Bilayer tablets allows for designing and modulating the dissolution and release
characteristics Bilayer tablets are prepared with one layer of drug for immediate release
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while second designed to release drug later, either as second dose or in an extended
release manner.
3.2. Heterogenous type

Bilayer tablet is suitable for sequential release of two drugs in combination, separate two
Incompatible substances.
Fig.3 Bilayer tablets (with two different drugs-heterogenous)
4. Need of bilayer tablets[5]

Controlling the delivery rate of either single or two different active pharmaceutical
ingredients.

To separate incompatible Active pharmaceutical ingredient (APIs) from each other, to
control the release of API from one layer by utilizing the functional property of the other
layer.

To modify the total surface area available for active pharmaceutical ingredient layer
either by sandwiching with one or two inactive layers in order to achieve
swellable/erodible barriers for modified release.

For the administration of fixed dose combinations of different active pharmaceutical
ingredient, prolong the drug product life cycle, buccal/mucoadhesive delivery system,
fabricate novel drug delivery system such as chewing device and floating tablet for
gastro-retentive drug delivery.
5. General properties of bilayer tablet dosage form[6,7]

Bilayer tablet should have the chemical and physical stability to maintain its physical
attributes over time.

Bilayer tablet should have sufficient strength to withstand mechanical shock during its
production, packaging, shipping and dispensing.
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
Bilayer tablet should have elegant product identity while free of defect like chips, cracks,
discoloration and contamination.

Bilayer tablet must be able to release the medicinal agents in a predictable and
reproducible manner.
6. Various techniques involved in formulation[8,9,10]
6.1. OROS® push pull technology
Fig.4 OROS Push Pull Technology

This system consist of mainly two or three layer among which the one or more layer are
essential of the drug and other layer are consist of push layer. The drug layer mainly
consists of drug along with two or more different agents. So this drug layer comprises of
drug which is in poorly soluble form. There is further addition of suspending agent and
osmotic agent. A semi permeable membrane surrounds the tablet core.
6.2. L-OROS® technology

The L-OROS® system was designed to provide continuous delivery of liquid drug
formulations and improve bioavailability of the drugs. L-OROS system consists of two
types i.e., soft gelatin capsule (SoftcapTM) and hard gelatin capsule (HardcapTM). Both
have a drug layer, barrier layer and a push layer surrounded by a semipermeable
membrane with a delivery orifice. The L-OROS hardcap system was designed to
accommodate more viscous suspensions with higher drug loading than softcap design.
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Fig.5 L-OROS® technology
6.3. EN SO TROL technology
Fig.6 EN SO TROL technology

Solubility enhancement of an order of magnitude or to create optimized dosage form
Shire laboratory use an integrated approach to drug delivery focusing on identification
and incorporation of the identified enhancer into controlled release technologies.
6.4. DUREDAS™ technology
 DUREDAS or Dual Release Drug Absorption System (Elan Corporation) utilizes bilayer
tableting technology, which has been specifically developed to provide two different
release rates or dual release of a drug from a single dosage form. The tablets are prepared
by two separate direct compression steps that combine an immediate release granulate (for
rapid onset of action) and a controlled release hydrophilic matrix complex within one
tablet. The controlled release matrix remains intact and slowly absorbs fluid from the GI
tract, which causes the matrix.
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 To expand and transforms the hydrophilic polymers into a porous, viscous gel that serves
as a barrier between the drug and the surrounding fluid. As the gel continues to expand,
fluid penetrates further into the dosage form, dissolving the drug and allowing the resulting
solution to diffuse out in a controlled manner. A further extension of the DUREDAS
technology is the production of controlled release combination dosage forms whereby two
different drugs are incorporated into the different layers, and the drug release of each layer
is controlled to maximize therapeutic effect of the combination. Again both immediate
release and controlled release combinations of the two drugs are feasible.
6.5. DUROS technology
Fig.7 DUROS
 DUROS (Alza Corporation) is based on implant technology, which provides an alternative
for the delivery of a wide range of therapeutic compounds, including peptides, proteins,
and other bioactive macromolecules. These implants are miniature titanium cylinders
designed to provide continuous osmotically driven delivery of drugs within the body for
up to one year. Following implantation, DUROS implants enable continuous, precise
delivery of the therapeutic compound at rates as low as 1% of a drop of water per day. The
cylinder is manufactured from titanium because of the material’s tolerability to human
tissue and its long use in medical devices such as implantable defibrillators and joint
replacements. The cylinder protects therapeutic agents from degradation in the body and
enables a drug to remain stable for extended periods of time. Recently, Viadur (leuprolide
acetate implant), which is based upon this technology, has been approved for once yearly
palliative treatment of advanced prostate cancer.
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6.6. PRODAS technology
 PRODAS or Programmable Oral Drug Absorption System (Elan Corporation) is a
multiparticulate drug delivery technology that is based on the encapsulation of controlled
release minitablets in the size range of 1.5 to 4 mm in diameter. This technology represents
a combination of multiparticulate and hydrophilic matrix tablet technologies and thus
provides the benefits of both these drug delivery systems in one dosage form. Minitablets
with different release rates can be combined and incorporated into a single dosage form to
provide the desired release rates. These combinations may include immediate release,
delayed release, and/or controlled release minitablets. In addition to controlled absorption
over a specified period, PRODAS technology also enables targeted delivery of drug to
specified sites of absorption throughout the GI tract. Combination products also are
possible by using minitablets formulated with different active ingredients
7. Various approaches for layered tablets[11,12]
7.1. Multilayered tablets (Bi, Tri)
 When two or more active pharmaceutical ingredients are needed to be administered
simultaneously and they are incompatible, the best option for the formulation pharmacist
would be to formulate multilayered tablet. It consists of several different granulations that
are compressed to form a single tablet composed of two or more layers and usually each
layer is of different colour to produce a distinctive looking tablet. Dust extraction is
essential during compression to avoid contamination. Therefore, each layer undergoes
light compression as each component is laid down. This avoids granules intermixing if the
machine vibrates.
Fig.8 Bilayer tablets, Tri layer tablets
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7.2. Compression coated tablet

This type of tablet has two parts, internal core and surrounding coat. The core is small
porous tablet and -prepared on one turret. For preparing final tablet, a bigger die cavity in
another turret is used in which first the coat material is filled to half and then core tablet is
mechanically transferred, again the remaining space is filled with coat material and
finally compression force is applied. This tablet readily lend itself in to a repeat action
tablet as the outer layer provides the initial dose while the inner core release the drug later
on. But, when the core quickly releases the drug, entirely different blood level is achieved
with the risk of over dose toxicity. To avoid immediate release of both the layers, the core
tablet is coated with enteric polymer so that it will not release the drug in stomach while,
the first dose is added in outer sugar coating. Even so, coating operation requires
interpretation while manufacturing and dawdling the manufacturing process. Sometimes,
inner core may be of liquid formulation to provide immediate release of core after the
coat gets dissolved.
Fig.9 Core coated tablets
7.3. Inlay tablet

A type of layered tablet in which instead the core tablet being completely surrounded by
coating, top surface is completely exposed. While preparation, only the bottom of the die
cavity is filled with coating material and core is placed upon it. When compression force
is applied, some coating material is displaced to form the sides and compress the whole
tablet. To reduce capital investment quite often existing but modified tablet presses are
used to develop and produce such tablets. The development and production of quality
bilayer tablets needs to be carried out on purpose-built tablet presses to overcome
common bi-layer problems. Using a modified tablet press may therefore not be your best
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approach to producing a quality bi-layer tablet under GMP conditions. Especially when in
addition high production output is required.
Fig.10 Inlay tablets
8. Quality and GMP requirements[13]
 To produce a quality bilayer tablet, in a validated and GMP-way, it is important that the
selected press is capable of.
 Providing sufficient tablet hardness.
 Preventing cross-contamination between the two layers.
 High yield.
 Producing a clear visual separation between the two layers.
 Preventing capping and separation of the two individual layers that constitute the bi-layer
tablet.
9. Types of bilayer tablet press[14,15,16]
9.1. Single sided press
 The simplest design is a single-sided press with both chambers of the double feeder
separated from each other. Each chamber is gravity- or forced-fed with a different powder,
thus producing the two individual layers of the tablet. When the die passes under the
feeder, it is at first loaded with the first-layer powder followed by the second-layer
powder. Then the entire tablet is compressed in one or two (pre and main-compression)
steps. The two layers in the die mix slightly at their interface and in most cases bond
sufficiently so that no layer-separation occurs when the tablet is produced.
Limitation of single sided press
 No weight monitoring/control of the individual layers.
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 No distinct visual separation between the two layers.
 Very short first layer-dwell time due to the small compression roller, possibly resulting in
poor de-aeration, capping and hardness problems.
Dwell time
 Dwell time is defined as the time during which compression force is above 90% of its peak
value. Longer dwell times are a major factor in producing a quality tablet, especially when
compressing a difficult formulation.
9.2. Double-sided tablet press
 A double-sided press offers an individual fill station, pre-compression and main
compression for each layer. Most double-sided tablet presses with automated production
control use compression force to monitor and control tablet weight. The effective peak
compression force exerted on each individual tablet or layer is measured by the control
system at main-compression of that layer. Measured peak compression force (under
constant thickness) is the signal used by the control system to reject out-of-tolerance
tablets and correct the die fills depth when required.
Limitations of compression force controlled system
 Many bilayer formulations require less than 100 daN to compress first layer in order to
retain the ability to bond with the second layer.
 Above 100 daN, this ability may be lost, bonding between both layers may not be
sufficient, resulting in low hardness of the bilayer tablet and separation of the two layers.
10.3
Bilayer tablet press with displacement monitoring
 The displacement tablet weight control principle is fundamentally different from the
principle based upon compression force. When measuring displacement, the control
system sensitivity does not depend on the tablet weight but depends on the applied pre
compression force.
 This double-sided tablet press has been specifically designed and developed for the
production of quality bilayer tablets and provides.
 ‘Displacement’ weight monitoring/control for accurate and independent weight control of
the individual layers.
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 Low compression force exerted on the first layer to avoid capping and separation of the
two individual layers.
 Increased dwell time at pre-compression of both first and second layer to provide
sufficient hardness at maximum turret speed.
 Maximum prevention of cross-contamination between the two layers - a clear visual
separation between the two layers – maximized yield.
10. Preparation of bilayer tablet[16,23,24]
 Bilayer tablets are prepared with one layer of drug for immediate release with the second
layer designed to release drug later, either as a second dose or in an extended release form.
The bilayer tablets with two incompatible drugs can also be prepared by compressing
separate layers of each drug so as to minimize area of contact between two layers. An
additional intermediate layer of inert material may also be included.
Compression: It is defined as reduction in bulk volume by eliminating voids and bringing
particles into closer contacts.
Consolidation: It is the property of the material in which there is increased mechanical
strength due to interparticulate interaction (bonding). The compression force on layer 1 was
found to be major factor influencing tablet delamination.
Fig.11 Preparation of bilayer tablet Compaction
11. Characterization of bilayer tablet[17,18]
Particle size distribution
The particle size distribution was measured using sieving method.
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Photo microscope study
Photo-microscope image of TGG and GG was taken (×450 magnifications) by
photomicroscope.
Angle of repose
The diameter of the powder cone was measured and the angle of repose was calculated using
the following equation.
Tan θ = h/r
Where h and r are the height and radius of the powder cone.
Moisture sorption capacity
All disintegrates have capacity to absorb moisture from atmosphere which affects moisture
sensitive drugs. Moisture sorption capacity was performed by taking 1 g of disintegrate
uniformly distributed in petri-dish and kept in stability chamber at 37±1ºC and 100% relative
humidity for 2 days and investigated for the amount of moisture uptake by difference
between weights.
Density
The loose bulk density (LBD) and tapped bulk density (TBD) were determined and
calculated using the following formulas.
LBD 1/4 weight of the powder = volume of the packing
TBD 1/4 weight of the powder = tapped volume of the packing
Compressibility
The compressibility index of disintegrate was determined by Carr’s compressibility index.
12. Evaluation of bilayer tablet[17,18,19]
Tablet Thickness and Size
Thickness and diameter of tablets were important for uniformity of tablet size. Thickness and
diameter was measured using venire caliper.
Tablet Hardness
The resistance of tablets to shipping or breakage under conditions of storage, transportation
and handling before usage depends on its hardness. The hardness of tablet of each
formulation was measured by Monsanto hardness tester. The hardness was measured in
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kg/cm2. Other tester used to check tablet hardness are strong-cubb tester, Pfizer tester the
Erweka tester and Schleuniger tester.
Friability
Friability is the measure of tablet strength. Electrolab EF- 2 friabilator (USP) was used for
testing the friability using the following procedure. Twenty tablets were weighed accurately
and placed in the tumbling apparatus that revolves at 25 rpm dropping the tablets through a
distance of six inches with each revolution. After 4 min, the tablets were weighed and the
percentage loss in tablet weight was determined. % loss = [(Initial wt. of tablets – Final wt. of
tablets)/ Initial wt. of tablets] ×100
Uniformity of Weight
Twenty tablets were selected at random and the average weight was calculated. Weight
Variation was calculated and was compared with I. P. standards.
Dissolution Studies
Bilayer tablets were subjected to in vitro drug release studies in simulated gastric and
intestinal fluids to assess their ability in providing the desired controlled drug delivery. Drug
release studies were carried out using USP dissolution test apparatus I at 100 rpm, 37±0.5°C,
and pH 1.2 buffer (900 ml) (i.e. 0.1 N HCl) for 2 hours, since the average gastric emptying
time is about 2 hours. The dissolution medium was replaced with pH 6.8 phosphate buffer
(900 ml) and experiment continued for another 10 hours. At different time intervals, 5ml of
the samples were withdrawn and replaced with 5ml of drug-free dissolution medium. The
samples withdrawn were analyzed by UV spectrophotometer using multi component mode of
analysis.
13. Various approaches used in the bilayer tablet[20,21,22]
Floating drug delivery system

From the formulation and technological point of view, the floating drug delivery systems
are considerably easy and logical approach in the development of Gastro retentive dosage
forms (GRDFs).
Approaches to design floating drug delivery system
Intra gastric bilayer floating tablets: These are also compressed tablet as shown in figure
and contain two layers i.e. Immediate and sustained release.
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Multiple unit type floating pills: These systems consist of sustained release pills as ‘seeds’
surrounded by double layers. The inner layer consists of effervescent agents while the outer
layer is of swellable membrane layer. When the system is immersed in dissolution medium at
body temperature, it sinks at once and then forms swollen pills like balloons, which float as
they have lower density.
Fig.12 Multiple units of oral FDDS
Polymeric bio adhesive system
 These are designed to imbibe fluid following administration such that the outer layer
becomes a viscous, tacky material that adheres to the gastric mucosa/mucus layer. This
should encourage gastric retention until the adhesive forces are weakened. These are
prepared as one layer with immediate dosing and other layer with bio adhesive property.
Swelling system
 These are designed to be sufficiently small on administration so as not to make ingestion
of the dosage form difficult (e.g., less than approximately 23 mm long and less than 11
mm wide for an oval or capsule –shaped tablet whereas 10- 12mm in diameter for round
tablets). On ingestion they rapidly swell or disintegrate or unfold to a size that precludes
passage through the pylorus until after drug release has progressed to a required degree.
Gradual erosion of the system or its breakdown into smaller particles enables it to leave
stomach. The simple bilayer tablet may contain an immediate release layer with the other
layer as extended release or conventional release.
SUMMARY
Bi-layer tablets provide one of the important design approaches where incompatible drugs,
with different indication, and same drug with different release rate (e.g. IR and ER) can be
incorporated in a single unit. Bi-layer tablet is improved beneficial technology to overcome
the limitation of the single layered tablet. Bi-layer tablet is suitable for sequential release of
two drugs in combination, separate two incompatible substances and also for sustained
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release tablet in which one layer is immediate release as initial dose and second layer is
maintenance dose. The preparation of tablets in the form of multi layers is used to provide
systems for the administration of drugs, which are incompatible and to provide controlled
release tablet preparations by providing surrounding or multiple swelling layers. Bilayer
tablet quality and GMP-requirements can vary widely. This explains why many different
types of presses are being used to produce bi-layer tablets, ranging from simple single sided
presses to highly sophisticated machines.
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an overview on bilayered tablet technology

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