Applications Of Liquid-Filled Capsules For Challenging APIs In Pharmaceutical Manufacturing

Liquid-filled capsules (LFCs) offer a scalable, efficient, and versatile solution for modern drug manufacturing, combining precision formulation with streamlined production. They are made using a straightforward encapsulation process, with shells typically crafted from gelatin or vegetarian alternatives like hydroxypropyl methylcellulose (HPMC), potato starch, or carrageenan.

The active pharmaceutical ingredient (API) is dissolved or suspended in a heated kettle with carefully chosen excipients such as triglycerides, polyethylene glycol, surfactants, and solubility enhancers. These ingredients improve bioavailability, ensure uniform distribution of the API, and stabilize the formulation. The mixture is then transferred to filling machinery to fill hard-shell capsules of varying sizes, sealed to prevent leaks, and cooled to solidify the contents.

This paper reviews the LFC manufacturing process and highlights scenarios where LFCs excel, offering unmatched benefits in addressing solubility challenges, enhancing bioavailability, and simplifying complex formulations. LFCs represent an innovative and patient-friendly solution for pharmaceutical development.