Paracetamol Grades: DC vs Powder vs Micronised

Paracetamol (acetaminophen, CAS 103-90-2) is the same molecule in every grade – what changes is the physical form. The form decides how the API flows, compacts and blends, and therefore which manufacturing process it suits. This page compares the main grades.

The grades at a glance

Grade	Form	Flow	Process it suits
Plain / powder	Fine crystalline powder	Poor	Wet/dry granulation
DC (direct compression)	Free-flowing granules	Good	Blend-and-compress
Micronised / fine	Very fine powder	Poor	Specialty dispersion needs

Plain (powder) grade

The standard crystalline form. It is the cheapest per kilogram but flows poorly and compacts poorly on its own, so a tablet manufacturer normally has to granulate it before compressing. That adds steps, equipment and variability – but it gives the formulator freedom over the granulation.

DC (direct-compression) grade

DC grades are granules engineered to flow and compact well, so they can be tabletted directly. The DC 90 grade is defined by its particle-size distribution and bulk density:

Parameter	DC 90
Appearance	White free flowing fine granules
Assay	87.5 – 92.5%
Bulk density	0.50 – 0.70 g/ml
Particle size	USS 20-80 distribution

The advantage is process simplicity: fewer unit operations and less risk of granulation variability, at a higher API cost.

Micronised / fine grade

A very fine grade, used where fine dispersibility or a specific dissolution behaviour is wanted. Because it flows even less well than the standard powder, it is used only where the process suits it.

How to choose

If you…	Consider
Compress directly	DC grade (e.g. DC 90)
Granulate in-house anyway	Plain powder grade
Need a different bulk density for the press	Another DC density
Need very fine dispersion	Micronised grade

The chemical specification (identification, assay, related substances, microbial limits) is common to all grades; the grade adds physical controls (form, particle size, bulk density) on top. Always confirm the grade and its particle-size/bulk-density values against your process.

Frequently Asked Questions

Is DC paracetamol different from plain paracetamol?

Chemically the same; physically different. DC grades are granules designed for direct compression, while plain grades are fine powders that usually need granulation.

Which grade is cheapest?

Plain powder is cheapest per kilogram, but DC grades can be cheaper overall because they skip a processing step.

What is a DC 90 grade?

A direct-compression granule of paracetamol with a defined particle-size distribution and a bulk density of 0.50 – 0.70 g/ml.

Do all grades meet the same specification?

They meet the same chemical specification; the grade adds physical controls such as particle size and bulk density.

Can I switch grades?

Only with care – a change of particle size or bulk density changes flow and compaction, so the compression process must be re-confirmed.