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Pharmaceutical OSD Powder & Granules Blending

The Matcon Blender is designed to produce superior blend homogeneity, achieving a blend uniformity (BU) that results in top quality tablets & capsules. The blender uses tumble mixing and diffusion mixing, which is equivalent to bin or conta blending that is well established within the pharmaceutical industry.

This approach gives manufacturers a reliable, repeatable process that supports consistent product quality across every batch. Whether you are blending simple formulations or complex low-API content mixes, the Matcon Blender delivers proven results.

Maintaining blend uniformity in these formulations is critical, as even minor variations can affect tablet potency and patient safety. The IBC system is built to handle this challenge without compromising throughput or adding complexity to your production process.

How Does the Matcon Blender Achieve Blend Uniformity?

Blend uniformity is one of the most important quality measures in oral solid dosage (OSD) manufacturing. The Matcon Blender uses diffusion or tumble mixing to gently and thoroughly combine powder ingredients inside the IBC. This method avoids aggressive mechanical mixing that can damage sensitive particles. The result is a consistent, homogeneous blend that meets the tight specifications required for tablet and capsule production.

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Proof of Mixing with PAT and NIR Technology

Near-infrared (NIR) technology can be added to the blender to deliver Process Analytical Technology (PAT) analytics that prove blend uniformity and optimize mixing times in real time. This means you are not relying on offline sampling or post-process testing alone. Instead, you get live data that confirms your blend is ready, reducing the risk of over- or under-blending. This level of in-process measurement supports regulatory compliance and gives quality teams the evidence they need for batch release.

Our test facilities around the world can be used to define the optimum blending parameters and generate equivalency documents to prove capabilities for formulation manufacturing.

Take a look at our case studies to see how we help our customers.

How Does IBC Blending Support Pharmaceutical OSD Production?

Using IBCs as the blending vessel removes the need to transfer powder between containers at different stages of production. The IBC that holds the blend also becomes the container for transporting, storing, and feeding powder to downstream processes such as tablet pressing. This approach reduces the number of manual handling steps, lowers the risk of cross-contamination, and keeps blend integrity intact right up to the point of use. It is a well-established method for improving both productivity and product quality in OSD manufacturing.

For manufacturers running multiple products or batch sizes, the flexibility of IBC blending is a significant advantage. You can read about how to get different batch sizes blended using the same pharmaceutical equipment to understand how this works in practice.

Key Features of the Matcon Blender for OSD Manufacturing

The Matcon Blender is built for pharmaceutical environments where space, hygiene, and performance all matter.

The Matcon range of blenders offer a reliable solution for pharmaceutical manufacturers, as they present the ability to run multiple IBC sizes on a single blender which adds flexibility to production planning. Learn more about how Matcon IBC technology supports pharmaceutical manufacturing and how it fits into a complete OSD production line.

  • Small footprint requiring less clean-room space
  • Accommodates a range of IBC sizes on one Blender
  • Compatible with NIR blend homogeneity measurement devices
  • Through-wall design capability to separate processes
  • High OEE rates - Overall Equipment Effectiveness is high for blending rates
  • Diffusion or tumble mixing mode
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Related Resources

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OSD Pharma Brochure

IBC Brochure

Cone Valve Technology Brochure

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A Better Way To Handle Tablets Using IBCs

Handling tablets in larger batches using IBCs reduces the amount of labour needed to move containers and make and break connections at each stage of the tablet finishing process. Fewer transfer events mean better control, stronger traceability and recording throughout tablet processing.

A single Tablet IBC can replace multiple drums and offers automatic filling capabilities, while reducing the risk of breakage or damage during transfer. For operations running high volumes of tablets, moving from drums to IBCs at the tablet handling stage delivers measurable improvements in throughput and production efficiency.

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Frequently Asked Questions About Pharmaceutical Blending in an IBC:

Blend uniformity (BU) refers to how evenly the active pharmaceutical ingredient (API) and excipients are distributed throughout a powder blend.

In tablet and capsule manufacturing, poor blend uniformity can lead to inconsistent dosing, which is a direct risk to patient safety. Regulatory bodies require manufacturers to demonstrate and document blend uniformity as part of their quality control processes.

Tumble blending mixes powders by rotating the IBC causing the powder bed to repeatedly divide and recombine. It is a gentle blending method and is widely used for blending free-flowing pharmaceutical powders when particle integrity must be preserved. This method is well suited to pharmaceutical blending because it is gentle on fragile particles.

Convective mixing uses impellers, paddles, ribbons, or other mechanical agitators to actively move material throughout the blend. This typically provides faster mixing and can be more effective for cohesive powders, but it may generate higher shear, heat, and particle attrition.

 

Yes, the Matcon Blender can handle low API content mixes. The Matcon Blender has a proven track record with low API content formulations, which are among the most demanding blending challenges in pharmaceutical manufacturing.

Achieving uniform distribution of a small quantity of active ingredient throughout a much larger volume of excipients requires a precise and controlled mixing process. 

Process Analytical Technology (PAT) is a framework used in pharmaceutical manufacturing to monitor and control production processes in real time.

Near-infrared (NIR) spectroscopy, when added to the Matcon Blender, provides continuous in-process measurement of blend homogeneity. This allows operators to confirm when the blend has reached the required uniformity and stop the process at exactly the right point, avoiding both under-blending and unnecessary over-blending.

The Matcon Blender is designed to accommodate a range of IBC sizes on a single unit. This means manufacturers can run different batch sizes using the same blending equipment without needing separate machines for each volume.

The specific IBC sizes compatible with your blender setup can be confirmed during the test plant trial process, where blending parameters are defined for your exact requirements.

An Intermediate Bulk Container (IBC) blending system reduces downtime because the same container can be used for blending, storage, transport, and discharge. Once blending is complete, the IBC is simply removed from the blender drive and transferred directly to the next process step.

In contrast, with V-blenders and conta blenders, the product typically has to be discharged into another container for transport and downstream processing. This additional handling can increase changeover time, cleaning requirements, operator intervention, and risks product loss, cross-contamination or mix segregation.

The IBC approach keeps equipment running more of the time, which directly improving Blender OEE rates and reduces overall production downtime. You can read more about how to reduce downtime in pharmaceutical manufacturing to see the full impact that IBC Blending can have.

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