Reconcile core tablets against coated tablets obtained, on a tablet-count basis.
Coating reconciliation compares the number of core tablets fed into the coating pan against the number of coated tablets actually recovered — using tablet counts rather than raw weight, since the coating process itself adds weight to every tablet.
Because the average coated tablet weighs more than the average core tablet, a direct kilogram-to-kilogram comparison between the two stages would be misleading; this calculator instead derives an expected coated batch weight from the theoretical tablet count and the actual average coated tablet weight, so the reported weight loss reflects genuine tablet loss rather than the normal weight gain from coating.
This mirrors how coating reconciliation is typically documented in a batch manufacturing record — tablet count as the primary conservation check, with weight reported alongside it for cross-reference.
Coating is one of the more failure-prone steps for tablet loss — tablets can be lost to pan wall buildup, exhaust air entrainment of fines and chipped fragments, or rejection during a post-coating appearance check. Because weight alone doesn't tell the full story here, reconciliation formulas that convert both sides to a tablet-count basis are what most manufacturers actually rely on to catch a genuine shortfall.
Because coating adds weight to each tablet, a direct weight comparison would show an apparent 'gain' that masks any real tablet loss — tablet count stays comparable before and after coating.
Common causes include pan wall buildup, fines and chipped tablet fragments carried out with the exhaust air, and tablets rejected during appearance inspection.