A Review of Current Formulation Trends and Technological Advancements

Md Rehan Md Aqil*, Khalifa Mahmad Asif Yunus, Shaikh Azeem Hasddin

JIIU’s Ali Allana College of Pharmacy Akkalkuwa, Dist.-Nandurbar -425415, Maharashtra, India.

*Correspondence: srrehan0@gmail.com;

DOI: https://doi.org/10.71431/IJRPAS.2026.5101

INTRODUCTION

Since children and elderly patients frequently have trouble swallowing traditional solid oral dosage forms, fast-dissolving drug delivery systems were first launched in the late 1970s as an alternative to standard tablets, capsules, and syrups. Among these novel techniques, fast-dissolving films have become a viable choice for oral drug delivery since they are easier to use and more convenient than other forms, such as sublingual, buccal, and orally disintegrating tablets. The thin, solid strips that make up these mouth-dissolving films disintegrate quickly in the oral cavity in a matter of seconds without the need for chewing or water. For drug ingestion, oral administration—usually in the form of tablets or capsules—remains the most popular and widely accepted method for people of all ages, including adults, children, and the elderly.[1]

The most popular method for systemic treatment is still oral drug delivery because of its ease of use, affordability, and high patient adherence. One of the most popular solid oral dosage forms is the tablet, which is valued for its precise dosage, convenience of production, and long shelf life. But a lot of people, especially kids, the elderly, and several patient groups, have dysphagia, which is a disorder that makes it difficult for them to swallow medications. Up to half of the population may have trouble swallowing conventional tablets or capsules, according to research, which could lead to poor treatment compliance. Fast dissolving tablets (FDTs), a cutting-edge drug delivery solution, have been introduced to address this problem. These tablets dissolve or disintegrate in the mouth in a matter of seconds, removing the need for water and making them perfect for patients who have trouble swallowing, such as elderly, pediatric, bedridden, and people who need to take their medications while on the go. [2]

Research on developing rapid-dissolving buccal tablets for better systemic absorption was the initial focus of the creation of fast dissolving tablets (FDTs). These early developments sought to circumvent the gastrointestinal tract (GIT) and first-pass hepatic metabolism, which frequently diminishes the efficacy of drugs, by enabling direct absorption through the mucosal membranes of the mouth. The benefits of FDTs include increased bioavailability and a faster therapeutic effect when a medicine is appropriate for buccal absorption. FDTs offer clinical advantages even if the medication is swallowed rather than efficiently absorbed through the buccal route. Compared to traditional solid dose forms, the tablet's quick dissolving and disintegration in the oral cavity guarantee a quicker release of the medication. This results in a faster beginning of action, which can be crucial for ailments like pain, allergies, or nausea that need to be treated right away. FDTs have pharmacokinetic advantages, but they also greatly increase patient comfort and adherence. The pill reduces the effort needed to swallow and does not require water because it dissolves into a liquid when it comes into touch with saliva.

Because of this, FDTs are particularly beneficial for patients who have trouble swallowing, including young children, elderly people, bedridden people, and those with mental disabilities. FDTs are especially well-liked by active people who might need to take medication while traveling or going about their everyday lives because of their convenience and simplicity of administration.[2]

PREPARATION OF FAST DISSOLVING TABLETS (FDTS)

The wet granulation process was used to create fast-dissolving tablets. After passing through a #60 mesh sieve, the active medication (FLB), superdisintegrants (sodium starch glycolate, L-hydroxypropyl cellulose, crospovidone, and croscarmellose), and four additional tablet excipients were completely combined in a plastic bag for five to ten minutes.

 Using starch paste as a binder, granulation was performed, and the wet mass was then run through a #18 sieve. A #22 sieve was then used to resize and dry the granules in order to guarantee consistency. The poly bag approach was used to lubricate these granules by combining talc and magnesium stearate for an additional five minutes. Using 7 mm round flat punches and a 16-station rotary tablet press (Cadmach, Ahmedabad, India), the finished blend was squeezed into tablets with a 3500 N compression force. [3]

EVALUATION OF TABLET PROPERTIES FOR FAST DISSOLVING TABLETS (FDTs)

1.      Weight Variation Test

• Ensures uniformity of tablet weight.

• Tablets are weighed individually, and the average weight is calculated.

 • Acceptable limits as per IP/BP/USP guidelines (±7.5% for tablets weighing 130–324 mg, etc.).

2.Hardness (Crushing Strength)

 • Measured in kg/cm² or Newtons.

 • FDTs should have sufficient strength to withstand handling but not so hard that it affects disintegration.

• Ideal range: 2–4 kg/cm².

3. Friability Test

• Indicates mechanical resistance.

• Tablets are rotated in a friabilator and weight loss is measured.

• Limit: ≤1% weight loss is acceptable. [2]

4. Thickness and Diameter

• Measured using a Vernier caliper or micrometer.

• Ensures uniformity in tablet dimensions.

5. Disintegration Time

• Key parameter for FDTs.

• Should disintegrate in the oral cavity within 60 seconds.

 • Measured using a disintegration apparatus without a disc or simulated saliva.

6. Wetting Time

• Measures how quickly the tablet absorbs moisture and starts to break.

• Shorter wetting time indicates better performance.

7. Water Absorption Ratio (R%)

 • Indicates the tablet’s ability to absorb moisture.

• Calculated using the increase in tablet weight after water absorption.

 8. In-vitro Dispersion Time

 • Measures how quickly the tablet disperses in a small volume of water.

            • Should be below 30 seconds for ideal FDT performance.

 9. Drug Content Uniformity

• Ensures each tablet contains the intended amount of drug.

 • % drug content should be within 85–115% of the label claim.

10. In-vitro Dissolution Test

• Measures the rate and extent of drug release.

 • Typically performed in 900 mL of phosphate buffer or simulated saliva at 37°C.

 • Helps predict bioavailability. [3]

11. Taste Evaluation

 • Important for patient compliance, especially in pediatric and geriatric use.

 • Often tested through a panel or electronic tongue systems. [4]

CRITERIA FOR FAST DISSOLVING DRUG DELIVERY SYSTEM

• Not require water to swallow, but it should dissolve or disintegrate in the mouth in matter of seconds.

 • Be compatible with taste masking

. • Be portable without fragility concern.

• Have a pleasant mouth feel.

• Leave minimum or no residue in the mouth after oral administration.

 • Exhibit low sensitive to environmental condition as temperature and humidity.

• The medication will dissolve and absorb quickly, resulting in a rapid commencement of effect.

 • As saliva travels down to the stomach, certain medications are absorbed from the mouth, throat, and esophagus. In certain situations, the drug's bioavailability is enhanced.

 • Pregastric absorption can enhance bioavailability and, as a result of lower dosage, improve clinical performance by minimizing side effects.

• A pleasant mouthfeel can assist patients, especially young ones, stop viewing medications as bitter pills. [6]

SALIENT FEATURES OF FAST DISSOLVING DRUG DELIVERY SYSTEM

            • Easy administration for individuals who have trouble swallowing traditional pills

 • Eliminates the need for water during intake.

• Ensures rapid drug dissolution and absorption, leading to a faster onset of therapeutic effect.

• Certain drugs can be absorbed directly through the mouth, pharynx, and esophagus during saliva flow, enhancing bioavailability and reducing side effects (pregastric absorption).

 • Offers a pleasant mouthfeel, improving patient compliance.[7]

BENEFITS OF FAST DISSOLVING TABLETS

• Anytime, wherever, and without the need for water.

• Suitability for elderly and young patients who have trouble swallowing, as well as for other groups that might have trouble using traditional oral dosage forms because they are mentally ill, developmentally disabled, uncooperative, on reduced liquid intake plans, or nauseated.

• Helpful in situations where an extremely quick beginning of action is needed, such as motion sickness, severe allergic attack episodes, or coughing.

• A higher bioavailability since these tablets dissolve and disintegrate quickly, especially for hydrophobic and insoluble medicines.

• Stability for a longer period of time because the medication stays in solid dose form until it is ingested. Thus, it combines the stability benefits of solid dosage forms with the bioavailability benefits of liquid dosage forms.

• FDT has all the benefits of solid dosage forms, including good stability, simplicity in production, uniform and precise dosing, ease of handling, etc.

 • Offers prompt medication therapy assistance.

• There is no chance that the dosing form will cause physical blockage.[8]

REQUIREMENTS OF FAST DISSOLVING TABLET

• Not require water to swallow because it should dissolve or disintegrate in the mouth within a few seconds.

 • Allow high drug loading

 • Have a pleasing mouth feel

• Leave minimal or no residue in the mouth after oral administration

• Exhibit low sensitivity to environmental conditions such as humidity and temperature

• Rapid dissolution of drug and absorption which may produce rapid onset of action.

·  Some drugs are absorbed form the mouth, pharynx and oesophagus as the saliva passes down into the stomach in such cases bioavailability of drugs is increased.

ADVANTAGES OF MOUTH DISSOLVING

 Mouth dissolving tablets are regarded as a unique medication delivery strategy because of the following benefits:

• High bioavailability and quick absorption are linked to nearly instantaneous pharmacological activity.

• Appropriate for those who have trouble swallowing, including elderly, young, and mentally ill individuals.

• It is possible to prevent stomach acid breakdown and first pass metabolism.

 • They have high bioavailability that is nearly similar to that of liquid dosage forms, but they are more stable than liquid dosage forms on average.

 • Oral delivery of conventional formulations reduces the danger of choking or asphyxia due to physical obstruction, improving safety. [10]

DISADVANTAGES OF MOUTH DISSOLVING

 MDTs have the following disadvantages:

 • The mechanical strength of the tablets is typically inadequate. Therefore, handling must be done carefully.

 • If the pills are not made correctly, they may leave a gritty or disagreeable taste in the mouth.

 • To ensure adequate stabilization and product safety, mouth dissolving pills require special packaging.[11]

• Because fast-dissolving tablets are hygroscopic, they should be stored in a dry environment.

 • There are moments when it has a mouth feeling.

• It also demonstrates the granules' delicate, effervescent quality. [2]

TECHNOLOGY USED FOR MANUFACTURING OF FAST DISSOLVING TABLETS

Various ways have been attempted to formulate fast dissolving tablets: [12]

Freeze-drying / Lyophilization

When the lyophilized or freeze-dried tablets come into contact with saliva, they breakdown or disintegrate quickly due to their high porosity. This method involves freezing the product and then sublimating the water out of it. A carrier or polymer's aqueous solution dissolves or disperses the active medication. Weighing and pouring the mixture into the prefabricated blister pack walls is how it is done. The medicinal solution or dispersion is frozen by passing the blister pack trays through a liquid nitrogen freezing tunnel. In order to lower the material's eutectic point, it is first frozen. To reduce the moisture to roughly 4% w/w of the dry product, primary drying is next carried out. In order to reduce the bound moisture to the necessary volume, secondary drying is done last. The lack of physical resistance in conventional blister packs is a significant drawback of the finished dose form. [11]

 Tablet Molding.

            Molded tablets are solid dispersion tablets. Since the dispersion matrix is typically composed of water-soluble carbohydrates, molded tablets dissolve more quickly and have a better flavor. Two varieties of molding processes exist: [1]. Solvent method: this technique creates a wetted mass by compressing the powder mixture under low pressure in molded plates after moistening it with a hydroalcoholic solvent. The solvent is eliminated by air drying. These tablets have a powder composition that speeds up dissolving and are less compact than compressed tablets.[2]. Heat method: a suspension comprising a medication, agar, and sugar (lactose or mannitol) is made using the heat molding technique. After pouring this suspension into the blister packing wells, the agar is allowed to solidify at room temperature to create a jelly before being vacuum-dried 7 at 30°C. The mechanical strength of these molded tablets is the primary concern, and binding agents can help achieve this.[13]

Spray drying

            This approach produces very tiny and porous particles as the processing solvent evaporates during the operation [11]. This method used mannitol as a bulking agent, sodium starch glycolate or croscarmellose sodium as a superdisintegrant, and hydrolyzed and nonhydrolyzed gelatin as a supporting matrix. By adding alkali compounds like sodium bicarbonate or acidic chemicals like citric acid, the rate of dissolution and disintegration was further boosted.A porous powder with a disintegration time of 20 seconds is the end product of this formulation process. Along with super disintegrants like croscarmellose, sodium starch glycolate, and crospovidone, and mannitol as a bulking agent, gelatin serves as a matrix and a supporting element in this process. In aqueous media, tablets composed of spray-dried powder that contains an alkaline (such as sodium bicarbonate), an acidic (citric acid), a bulking agent, and a superdisintegrant dissolve in less than 20 seconds. When this spray-dried powder was broken up into tablets, it broke down fast and was readily absorbed. [14]

Phase transition process

For the production of FDTs without the need for specialized equipment, it is determined that a phase transition during the manufacturing process and a combination of sugar alcohols with low and high melting points are crucial. Compressing powder containing erythritol (melting point: 122 °C) and xylitol (melting point: 93 95 °C) and heating it to roughly 93 °C for 15 minutes caused FDT to be created. The tablets' median pore size and hardness both increased upon heating. The crystal state of the lower melting point sugar alcohol had no bearing on how hard the tablets were when heated and stored. [15]

Mass Extrusion

This process uses a solvent mixture of methanol and water-soluble polyethylene glycol to soften the active blend. The softened mass is then expelled through a syringe or extruder to create a cylindrical extrude, which is then cut into even segments using a heated blade to create tablets. To hide the flavor of bitter medication granules, this method can also be applied.[16]

 Direct Compression

To create a solid oral dose form, the most preferred, difficult, and straightforward method is direct compression. When choosing to manufacture tablets using the direct compression technique, the most important factors are the fewest stages required, the low cost of the equipment employed, and the commonly used excipients. [22]. The method consists of two steps: the active ingredient (API) and excipients are combined, and a tableting machine is used to compact them.[17]

 Mass-Extraction

This process uses a solvent solution of methanol and water-soluble polyethylene glycol to soften the active mix. The resulting mass is then expelled through a syringe or extruder, which uses a heated blade to split a cylindrical product into even segments for tablet production. Water-soluble methanol and polyethylene glycol are used as a separate solvent to soften the active mixture. The resulting mass is then extruded using a syringe or extruder to produce a cylinder product. To create a tablet, the cylinder result is then divided into uniform pieces with a hot blade. Pellets of bitter medication can also be coated with the dried cylinder to mask their flavor.[18]

 Cotton candy process

The reason this method gets its name is because it uses a special spinning mechanism to create crystalline structures that resemble floss and resemble cotton candy. In the cotton candy technique, polysaccharide or saccharide matrices are created by spinning and flash melting at the same time. To increase its compressibility and flow characteristics, the resulting matrix undergoes partial re-crystallization. After being ground and combined with excipients and active substances, this candy floss matrix is compressed to FDT. This method offers better mechanical strength and can handle large medication dosages. However, the usage of this technique is limited by its high temperature. [19]

 Patented Technologies

Zydis Technology

Zydis formulation is a new technique for creating rapidly dissolving tablets. With this freeze-dried tablet method, the drug components are either physically contained or dispersed within the matrix of rapidly dissolving carrier polymers. When the "zydis unit" is placed in the mouth, the freeze-dried structure dissolves rapidly, therefore water is not required for ingestion. Zydis material is composed of many different compounds to achieve a number of objectives.Polymers like dextran are strengthened when handled by adding gelatin and alginate. Elegance, hardness, and crystallinity are enhanced by the use of saccharides like as mannitol or sorbitol. In order to prevent the "zydis unit" from shrinking during the freeze-drying process or during long term storage, collapse protectants like glycine are usually used. The composition should ideally be packaged in a blister to protect it from moisture.[18]

Durasolv Technology

CIMA LAB is the patent holder for this technique, which is based on direct compression technology and uses suitable excipients with improved qualities, especially superdisintegrants that accelerate the rate of disintegration and, consequently, dissolution (US patent no. 6,024,981). This technique is based on the use of 9 conventional non-direct compression fillers (such sorbitol, mannitol, and dextrose, among others) in the shape of small particles that dissolve quickly and don't leave the mouth feeling gritty or sandy. Water-soluble and sometimes effervescent materials can also help in the breakdown process. The DuraSolv® technology is designed to give stronger tablets without the requirement for packaging measures and can be packed in blisters. Fillers, lubricants, and therapeutic components make up the tablet in this technique.[20]

Flash Dose Technology

Fuisz is the patent holder of flash dosage technology. The first commercial product introduced by Biovail Corporation is the Nurofen meltlet, a novel version of ibuprofen in the form of melt-in-mouth tablets made with flash dosage technology. Flash dosage tablets are made of "floss," a self-binding shear-form matrix. Flash heat processing is used to create shear form matrices. Three oral medication delivery methods from Fuisz Technologies are associated with rapid dissolution. Chewing is necessary for the first two generations of quick-dissolving tablets, Soft Chew and EZ Chew. But these cleared the path for Flash Dose, Fuisz's most recent creation. Using a special spinning mechanism, the Flash Dose technology creates a crystalline structure that resembles cotton candy and floss. The active medication can then be incorporated into this crystalline sugar and crushed into a tablet. Shearform is the name of the process that Fuisz has patented. The finished product's surface area for dissolution isextremely large. Once on the tongue, it dissolves and spreads rapidly. It's interesting to note that the product's properties can be significantly changed by adjusting the temperature and other production-related factors. Rather than a substance that resembles floss, tiny spheres.[23]

Nanocrystal technolog

 The use of nanocrystals 5, 8, 15 With its patented nanocrystal technology, Elan can facilitate formulation and enhance compound activity and end product properties for fast-dissolving tablets. The surface area rises with decreasing particle size, increasing the rate of disintegration. Nanocrystal technology is a reliable and effective way to do this. Small drug material particles known as nanocrystal particles are created by milling the drug ingredient using a patented wet milling technology. These particles are usually smaller than 1000 nanometers (nm) in diameter.[23]

Pharmabust technology

SPI Pharma is the owner of the patent for Pharmaburst technology. By compressing a dry mixture containing a medication, flavoring, and lubrication, the tablets are created using this method, and they dissolve in 30 to 40 seconds. Because of their adequate potency, tablets made using this process can be packaged in bottles and blister packs.[23]

 Oraquick technology:

 The formulation of the oral dissolving pill uses the unique taste masking technology. The K V Pharmaceutical Company asserts that its flavor masking technology, known as microsphere technology, has a better mouthfeel than competing products. No solvents of any type are used in the taste masking process. Consequently, it results in faster and more effective output. Compression yields tablets with substantial mechanical strength without compromising taste masking. The only pharmaceutical company with products on the market is K V Pharmaceutical, which sells analgesics, cough and cold remedies, psychotic medications, and developing stage anti-infectives. [22]

Shearform Technology

"Floss," a shearform matrix, is created using this technology. Feedstock that has been produced using a sugar carrier is processed using flash heat. This method involves the simultaneous application of centrifugal force and a temperature gradient to sugar, which raises the mass's temperature and creates an internal flow state that allows some of the sugar to move in relation to the mass. When the floss is thrown, the rotating head allows the flowing mass to exit. The floss that is created has an amorphous texture. Therefore, using a variety of methods, it is further diced and recrystallized to provide a consistent flow and make mixing easier.After that, the active ingredient, matrix, and other excipients are mixed and compacted into tablets. Before recrystallizing the floss, the active medication and additional excipients might be mixed with it. [21]

CONCLUSION

A major advancement in medication delivery technology, Fast Dissolving Tablets (FDTs) are designed to dissolve quickly in saliva without the need for water. Their effectiveness and convenience are increased by their quicker beginning of action when compared to conventional pills. Patient adherence is significantly increased by the convenience of administration, especially for young patients, the elderly, and those who have dysphagia, or difficulty swallowing. FDTs are becoming more and more popular in the pharmaceutical business due to their many benefits over traditional dose forms. Children and elderly patients, as well as those who are bedridden, cognitively impaired, or have limited fluid intake, are particularly well-suited for them. The performance of FDTs has been further enhanced by improvements in manufacturing procedures, which have decreased possible disadvantages while increasing their stability, mechanical strength, and efficacy. These advancements have made it possible for FDTs to administer a variety of medications with enhanced therapeutic efficacy and bioavailability. FDTs provide a flexible and patient-friendly option by fusing the advantages of solid dose forms with the ease of liquids. Their promise as a preferred option in a variety of therapeutic domains is highlighted by their growing worldwide popularity. FDTs represent a significant advancement in contemporary pharmaceutical therapy by providing simplicity of use, quicker alleviation, and enhanced patient compliance.

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