Process to form an orally disintegrating tablet for human use

1. A process for the preparation of an orally disintegrating tablet for administration to a human subject, the tablet containing a medicinal substance to treat a disorder of the human subject, comprising the steps of:

providing a fluid formulation comprising the medicinal substance, a crystalline carrier material that is solid at room temperature and a gelator,

providing a solid element having formed therein at least one cavity,

cooling the solid element to a temperature below a freezing temperature of the formulation,

filling the cavity with the fluid formulation after said cooling,

solidifying the formulation while present in the cavity by extracting heat from the formulation through a cavity wall by conduction, to form a solid pellet comprising the medicinal substance without actively shaping the entire surface of the pellet, wherein the volume of the cavity is smaller than 50% of the volume of the pellet,

taking the pellet out of the cavity, and

drying the pellet in a vacuum to obtain the tablet.

2. A process according to claim 1 , characterised in that the formulation comprises 3 or more weight percent of the crystalline material and about 4 weight percent of the gelator.

3. A process according to claim 1 , characterised in that the gelator comprises a non gel-forming material.

4. The process according to claim 3 wherein the non-gel-forming material is a collagen derived material.

5. The process according to claim 4 , wherein the volume of the pellet is larger than a maximum volume of a free droplet of the fluid formulation at a temperature and pressure used when filling the cavity.

6. A process according to claim 4 , wherein the collagen derived material is a gelatine having a weight average molecular weight of 2×10 4 g/mol.

7. A process according to claim 1 , characterised in that the volume of the pellet is larger than a maximum volume of a free droplet of the fluid formulation at a temperature and pressure used when filling the cavity.

8. A process according to claim 7 , characterised in that a speed at which the cavity is filled with the fluid formulation is chosen such that the surface of the part of the pellet that is in the cavity before the pellet is taken out of the cavity, is in essence a negative print of the surface of the cavity.

9. A process according to claim 8 , characterised in that a measure is taken to support automatic detachment of the pellet from the cavity wall.

10. A process according to claim 9 , wherein the cavity is formed in a solid element characterised in that the automatic detachment is supported by keeping the temperature of the solid element adequately beneath the freezing temperature of the fluid formulation.

11. A process according to claim 1 , wherein a multiplicity of solid pellets is formed during said solidifying step and wherein the multiplicity of solid pellets are placed in a packed bed and arranged in a heat conducting container having a bottom and side walls, and that a heat source is provided above a top layer of the multiplicity of solid pellets, the heat source having a surface directed to a top layer of the bed, which surface has an emissivity coefficient of at least 0.4, whereafter the multiplicity of solid pellets are subjected to the vacuum while at the same time heating at least the bottom of the container and said surface to provide heat to the multiplicity of solid pellets to support drying of the multiplicity of solid pellets.