Unlocking Higher Complex Capsule Yields Through More Efficient Manufacturing

For complex multiparticulate products, small material losses at each manufacturing stage can accumulate, limiting final capsule output and making it harder to meet market demand. Adare Pharma Solutions identified an opportunity to improve the yield of a complex extended-release capsule without changing the formulation, equipment, or regulatory status.

By reevaluating material flow across a multi-stage bead layering process, the team developed a “top-up strategy” that supplemented expected losses with compatible intermediate beads at each manufacturing stage. The approach maximized batch size while remaining within the existing validated process, requiring no additional analytical testing or regulatory submissions.

The result was a 3–7% increase in final capsule output per batch across all product strengths, enabling greater product availability without additional batches or added strain on equipment and personnel.

Read the full case study to see how targeted process optimization can unlock meaningful manufacturing gains.