Syntegon expands the Sepion series with a pilot-scale tablet coater

The Sepion 75 expands the established Sepion series with a solution for pilot scale and supports pharmaceutical manufacturers in development and scale-up.

The new tablet coater scores with flexibility and processes batch sizes ranging from ten to 100 percent of the maximum working volume.

– Syntegon Completes Its Coater Portfolio with Sepion 75
– Flexible Batch Processing, Scalable Process Conditions, and Containment-Oriented Design Combined with Closed Material Handling
– Uniform Process Principles Enable Parameter Transfer to Production Scale and Reproducible Coating Results

Syntegon, a strategic lifecycle partner of the pharmaceutical and biotech industries, expands its portfolio for the manufacturing of solid oral dosage forms (Oral Solid Dosage, OSD) with the Sepion 75. The new pilot-scale tablet coater supports pharmaceutical manufacturers and CDMOs in efficiently managing a growing product variety, smaller and more variable batch sizes, and increasing containment requirements when processing highly potent active ingredients. With the new coater, Syntegon completes its established Sepion series, enabling consistent scale-up, faster and more flexible batch processing, and containment-oriented production.

The Sepion series is based on decades of experience in coating technology and combines proven process know-how with a machine concept designed to meet the demands of modern pharmaceutical production. “With the addition of a pilot plant, we support manufacturers in simplifying development and scale-up while maintaining uniform process principles across all production stages,” explains Fritz-Martin Scholz, Global Product Manager at Syntegon.

Flexible Batch Processing for Dynamic Production Requirements

To meet the increasing demands of modern production environments, the new tablet coater flexibly processes various batch sizes from ten to 100 percent of the maximum working volume. Two interchangeable drum sizes cover volumes from eight to 75 liters. This makes the Sepion 75 suitable for early development phases as well as pilot batches without the need to redefine process parameters. This facilitates production planning and reduces downtime during product changes.

An optimized drum geometry combined with an advanced spray system improves the utilization of process air and shortens process times. The automatically adjustable spray arm adapts its position to the fill level, contributing to reproducible coating conditions across different batch sizes—even in demanding applications such as functional coatings.

Closed Material Handling for Modern Containment Requirements

Furthermore, the entire Sepion series features closed material handling during filling, sampling, and emptying. By minimizing manual interventions, the machine concept allows containment-oriented processing of highly potent active ingredients. Optional containment features are available for all Sepion coaters up to OEB 5. These include split valves, safe-change filters, and extended cleaning concepts. These options enhance operator safety, reduce contamination risks, and ensure compliance with current regulatory requirements.

In addition to the Sepion 75, the series includes six other sizes with capacities ranging from 175 to 1,000 liters, covering the entire spectrum from development to commercial production.

Lifecycle Partner from Process Development to Service

As a strategic lifecycle partner of the pharmaceutical and biotech industries, Syntegon accompanies its customers throughout the entire lifecycle of their equipment—from process development and scale-up to qualification, modernization, and comprehensive service. With extensive process expertise and a global service network, Syntegon helps pharmaceutical manufacturers optimize their production performance, ensure reliable plant operation, and adapt their processes to changing market conditions and regulatory requirements.