Polymer vs Sugar Coating: When to Choose Each in Tablet Manufacturing
Once the decision to coat a tablet has been made, the next question is which coating technology to use. In food supplement manufacturing, the most common options are polymer coating and sugar coating. While both improve tablet appearance and user experience, they differ significantly in function, process complexity and manufacturing impact.
This article explains when polymer or sugar coating is typically chosen from a contract manufacturing perspective.
This article explains when polymer or sugar coating is typically chosen from a contract manufacturing perspective.
Coating type as a technical choice
In CMO projects, coating selection is rarely aesthetic-driven. Instead, it is evaluated based on:
In CMO projects, coating selection is rarely aesthetic-driven. Instead, it is evaluated based on:
- Formulation sensitivity
- Desired tablet performance
- Production scalability
- Packaging compatibility
Polymer coating: modern and functional
What is polymer coating?
Polymer coating involves applying a thin film made from polymer-based systems to the tablet surface. The coating is typically uniform and adds minimal weight or volume.
- Polymer coating is commonly selected when:
- Taste masking is required without significant tablet size increase
- Moisture or oxygen protection is needed
- Consistent appearance is important
- High-volume or repeatable production is planned
- It is widely used for:
- Multivitamin and multimineral tablets
- Amino acid formulations
- Tablets packaged in jars or bottles
Manufacturing advantages of polymer coating
From a CMO perspective, polymer coating offers:
- Relatively short coating times
- Controlled and repeatable processes
- Minimal increase in tablet dimensions
- Compatibility with automated production lines
- Polymer coatings are generally easier to integrate into scalable manufacturing workflows.
Limitations of polymer coating
Polymer coating may be less suitable when:
- Very strong taste masking is required
- A thick, smooth surface is desired for branding reasons
- Traditional appearance is part of product positioning
Sugar coating: traditional and sensory-driven
What is sugar coating?
Sugar coating involves applying multiple layers of sugar-based solutions to build up a smooth, rounded tablet surface. This process significantly increases tablet size and weight.
- When sugar coating is typically usedSugar coating is usually selected when:
- Strong taste masking is required
- A smooth, rounded mouthfeel is desired
- Traditional or classic product appearance is important
- It has historically been used for:
- Bitter formulations
- Herbal or botanical tablets
- Products targeting consumers sensitive to taste
- Limitations of sugar coatingFrom a manufacturing standpoint, sugar coating:
- Increases tablet size significantly
- Adds substantial process time
- Increases variability risk
- Limits production throughput
Comparison: polymer vs sugar coating
Polymer coating
- Thin, lightweight coating
- Faster and more scalable process
- Suitable for modern production lines
- Minimal impact on tablet size
Sugar coating
- Thick, multi-layer coating
- Excellent taste masking
- Slower, more complex process
- Significant increase in tablet size
Impact on packaging and logistics
Coating choice influences downstream operations:
- Polymer-coated tablets work well in blisters and jars
- Sugar-coated tablets often require more space and careful handling
Choosing between polymer and sugar coating
Polymer coating is typically chosen when:
- Scalable production is required
- Minimal size increase is desired
- Consistent appearance matters
- Strong taste masking is essential
- Traditional look and mouthfeel are priorities
- Production volume is moderate
FAQ: Polymer vs Sugar Coating
In many modern supplement products, polymer coating is preferred due to scalability and efficiency. Sugar coating is still used in specific cases where sensory properties are critical.
Sugar coating generally provides stronger taste masking, but polymer coatings can be sufficient for many formulations, especially when combined with flavour optimisation.
Yes. Polymer coatings add minimal thickness, while sugar coatings significantly increase tablet size and weight.
Not always. The formulation, tablet strength and target performance determine which coating technologies are feasible.
CMOs evaluate coating technology based on formulation behaviour, manufacturing feasibility, production scale and packaging compatibility rather than appearance alone.