--- title: Optimize your profitability with hard-shell caps | CapsCanada description: With support from the right partner, drug manufacturers can increase productivity and optimize the profitability of oral solid dosage formulations. image: https://blog.lyfegroup.com/hubfs/6-mini-portada.jpg --- [![Logo-LyfeGroup-blue](https://blog.lyfegroup.com/hs-fs/hubfs/Logo-LyfeGroup-blue.png?width=800&height=169&name=Logo-LyfeGroup-blue.png)](https://blog.lyfegroup.com/) [![Logo-LyfeGroup-blue](https://blog.lyfegroup.com/hubfs/Logo-LyfeGroup-blue.png)](https://blog.lyfegroup.com/) - [Company](https://capscanada.com/company/?_gl=1*lcqm70*_gcl_au*NjgyNjM5Njk4LjE3Mzc0OTIzMzI.) - [Contact](https://capscanada.com/contact/?_gl=1*lcqm70*_gcl_au*NjgyNjM5Njk4LjE3Mzc0OTIzMzI.) - [Jobs](https://capscanada.com/careers/?_gl=1*lcqm70*_gcl_au*NjgyNjM5Njk4LjE3Mzc0OTIzMzI.) - [Industries](https://capscanada.com/markets/) - [Pharmaceutical](https://capscanada.com/pharmaceuticals/) - [Nutraceutical](https://capscanada.com/nutraceuticals/) - 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We have a new image, but the same team, products and quality as always. | CapsCanada is now Lyfe Group. We have a new image, but the same team, products and quality as always. | CapsCanada is now Lyfe Group. We have a new image, but the same team, products and quality as always. | CapsCanada is now Lyfe Group. We have a new image, but the same team, products and quality as always. | CapsCanada is now Lyfe Group. We have a new image, but the same team, products and quality as always. | CapsCanada is now Lyfe Group. We have a new image, but the same team, products and quality as always. | CapsCanada is now Lyfe Group. We have a new image, but the same team, products and quality as always. | CapsCanada is now Lyfe Group. We have a new image, but the same team, products and quality as always. | CapsCanada is now Lyfe Group. We have a new image, but the same team, products and quality as always. | ![How to optimize profitability in drug product manufacturing with hard-shell capsules](https://blog.lyfegroup.com/hubfs/6-portada--1920x700.jpg "How to optimize profitability in drug product manufacturing with hard-shell capsules") - [Technical Services](https://blog.lyfegroup.com/tag/Technical-Services) # How to optimize profitability in drug product manufacturing with hard-shell capsules Posted by [Steve Lee](https://blog.lyfegroup.com/author/steve-lee) on Oct 25, 2018, 6:21:00 p.m. When evaluating different dosage forms, it is clear that hard-shell capsules provide significant advantages over tablets and pressed pills: they are more simple to formulate and easier to produce.With support from the right partner[in terms of quality, technical services and training](https://capscanada.com/services/), drug manufacturers can increase productivity and optimize the profitability of oral solid dosage formulations. ## Hard-shell benefits   The use of hard capsules simplifies the development and manufacturing of solid oral dosage forms. Compared with other OSD manufacturing, the hard-shell capsule production process is relatively simple (filling of the capsule body, placement of the cap on the body and sealing/banding). Formulation is also easier, and raw material costs tend to be lower because fewer excipients are required. Preparation of product for filling into capsules is also generally less intensive compared to granulation. Tablet presses apply more stress on the active ingredient, and tablet formulations must address the challenges of flow, compressibility (without sticking), friability and bioavailability through proper dissolution. The capabilities of the two-piece capsule and filling process naturally overcome most of these obstacles. Most tablets are also subjected to a coating process, which introduces additional opportunities for process failure. The [simplified nature of capsule production](https://www.researchgate.net/publication/298789008_Capsules_and_It's_Technology_An_Overview) facilitates process transfer and scale-up. The same formulation can be used on low output and high-speed capsule filling machines — this is not often the case when switching from low- to high-speed tablet presses.   ## Practical steps to avoiding defects   Empty capsules with pre-existing defects can negatively impact the capsule filling process. Capsules must be dimensionally correct with consistent wall thicknesses and also be impeccably round to ensure that the body and cap are joined properly. Defective capsules can get stuck in the filling machine and may also lead to defects in the filled capsules, such as splits, pinholes, cap tucks and body folds — all of which can result in under-filled capsules, increasing the amount of loss per batch. When these defects occur, operators are challenged to identify the source. Large particle sizes in the formulation, worn tooling in the capsule filler, weak sidewalls in the capsules or poor setup of the machine must be considered when troubleshooting. Problem-solving requires stopping the machine to diagnose the issue, where downtime can be significant.   [![HPMC capsules](https://no-cache.hubspot.com/cta/default/7215323/b292138e-f940-4d8b-9b09-9923cbecd4d2.png)](https://cta-redirect.hubspot.com/cta/redirect/7215323/b292138e-f940-4d8b-9b09-9923cbecd4d2)   A quality capsule supplier will utilize automated inspection equipment to remove visibly identifiable nonconformities, an approach that reduces defect levels far beyond traditional acceptance quality limit (AQL) criteria. Testing of fill materials in advance to make sure that they have the appropriate properties is strongly advised. Documenting equipment settings is also important to ensure consistent operation from batch to batch, and reduces setup time and material. During product setup, ensure machine and capsule performance first by running the empty capsules through each step of the process to verify that rectification, closing and ejecting all run smoothly before introducing the fill material. ## Leveraging continuous improvement   Utilizing continuous improvement, such as holding Kaizen events, or short improvement projects, helps everyone work synergistically on common goals, providing an opportunity to discuss problems, identify root causes and propose solutions.   ***Keep learning about capsule technology trends...*** - [How CapsCanada Ensures Reliable Capsule Supply ](https://blog.lyfegroup.com/reliable-capsule-supply-capscanada) - [Pharmaceutical vs Nutraceutical Capsules: Key Differences Manufacturers Must Consider ](https://blog.lyfegroup.com/pharmaceutical-vs-nutraceutical-capsules-capscanada) - [Technical Trouble? How We Support Your Manufacturing Team ](https://blog.lyfegroup.com/technical-trouble-how-we-support-your-manufacturing-team)   ## The secret to fully optimized manufacturing   The processing benefits for hard capsules can only be fully realized if high-quality capsules, finely tuned filling machines and effective processes are utilized by highly trained operators. Lyfe Group customers benefit from the extensive expertise of our technical service team, whose members each have 20+ years of experience working with a range of equipment and formulation types. Our Technical Services Team dramatically improves operations productivity — in one case, a client shared their experience where  Lyfe Group training helped reduce capsule inspections by nearly 75%, while increasing run rates and efficiencies.  Lyfe Group offers several levels of training, including monthly webinars, on-site classroom education and hands-on machine training. The numerous benefits of hard-shell capsules are best realized through collaboration with a partner that has expertise in all aspects of formulation and production. Become a  Lyfe Group Partner by switching to our premium hard-shell capsules and take advantage of the extensive training and technical support we offer to our customers at no cost. Reduce expenses and optimize your capsule production with  Lyfe Group.   [![Contact Us](https://no-cache.hubspot.com/cta/default/7215323/7f37dd4c-36a6-44d0-a1d4-56b2c007cad6.png)](https://cta-redirect.hubspot.com/cta/redirect/7215323/7f37dd4c-36a6-44d0-a1d4-56b2c007cad6) CapsCanada is proudly part of [Lyfe Group](https://lyfegroup.com/), a global organization specializing in life sciences solutions for the nutraceutical and pharmaceutical markets. Leveraging capsule manufacturing excellence, technical guidance, and end-to-end supply coordination, Lyfe Group supports brands in developing innovative health products for global distribution.   Topics: [Technical Services](https://blog.lyfegroup.com/tag/technical-services) ## Related blogs [![](https://blog.lyfegroup.com/hubfs/image-blog-Faulty%20Capsule%20Ejection.jpg)](https://blog.lyfegroup.com/how-faulty-capsule-ejection-systems-ensure-product-quality) ### [Technical Tip: Faulty Capsule Ejection](https://blog.lyfegroup.com/how-faulty-capsule-ejection-systems-ensure-product-quality) Modern capsule filling equipment is designed to remove capsules which do not separate. This is important because we do... [Read More](https://blog.lyfegroup.com/how-faulty-capsule-ejection-systems-ensure-product-quality) [![Technical Support Services for Capsule Manufacturing | CapsCanada](https://blog.lyfegroup.com/hubfs/image-blog-technical-trouble-how-we-support-your-manufacturing-team.jpg)](https://blog.lyfegroup.com/technical-trouble-how-we-support-your-manufacturing-team) ### [Technical Trouble? How We Support Your Manufacturing Team](https://blog.lyfegroup.com/technical-trouble-how-we-support-your-manufacturing-team) Technical issues during encapsulation can directly impact productivity, lead times, and product integrity. **Lyfe Group** ... [Read More](https://blog.lyfegroup.com/technical-trouble-how-we-support-your-manufacturing-team) [![](https://blog.lyfegroup.com/hubfs/image-blog-capsulle-filling-separation-part-2.jpg)](https://blog.lyfegroup.com/capsule-filling-adjusting-separation-pins-for-precision) ### [Capsule Filling- Separation, part 2](https://blog.lyfegroup.com/capsule-filling-adjusting-separation-pins-for-precision) Some modern capsule filling machines are equipped with separation pins. These pins cycle up through the vacuum shoe... [Read More](https://blog.lyfegroup.com/capsule-filling-adjusting-separation-pins-for-precision) [![](https://blog.lyfegroup.com/hubfs/image-blog-capsule-filling-defects-causes-and-how-to-prevent-them.jpg)](https://blog.lyfegroup.com/capsule-filling-defects-capscanada) ### [Capsule Filling Defects: Causes and How to Prevent Them](https://blog.lyfegroup.com/capsule-filling-defects-capscanada) Producing high-quality capsule shells is just the first step in delivering a flawless product. The next critical stage—... [Read More](https://blog.lyfegroup.com/capsule-filling-defects-capscanada) [![](https://blog.lyfegroup.com/hubfs/image-blog-5-reasons-to-choose-capscanada-capsules.jpg)](https://blog.lyfegroup.com/reasons-to-choose-capscanada-capsule-solutions) ### [5 Reasons to Choose CapsCanada Capsules](https://blog.lyfegroup.com/reasons-to-choose-capscanada-capsule-solutions) When it comes to capsules, not all suppliers are created equal. Are you partnering with the right one?Whether you're... [Read More](https://blog.lyfegroup.com/reasons-to-choose-capscanada-capsule-solutions) [![](https://blog.lyfegroup.com/hubfs/image-blog-best-practices-storing-packaging-transporting.jpg)](https://blog.lyfegroup.com/best-practices-for-storing-packaging-and-transporting-capscanada-capsules-k-caps-and-g-caps-guide) ### [Best Practices for Storing, Packaging, and Transporting CapsCanada Capsules - Guide](https://blog.lyfegroup.com/best-practices-for-storing-packaging-and-transporting-capscanada-capsules-k-caps-and-g-caps-guide)  Lyfe Group's capsules, including K-CAPS® (HPMC-based) and G-CAPS® (gelatin-based), are crafted to meet the highest... [Read More](https://blog.lyfegroup.com/best-practices-for-storing-packaging-and-transporting-capscanada-capsules-k-caps-and-g-caps-guide) [![](https://blog.lyfegroup.com/hubfs/capsule-filling_separation-mobile.jpg)](https://blog.lyfegroup.com/capsule-filling-separation) ### [Capsule Filling: Separation](https://blog.lyfegroup.com/capsule-filling-separation) As the rectified capsule descends with optimal alignment into the upper segment bore, the separation phase begins.... [Read More](https://blog.lyfegroup.com/capsule-filling-separation) [![](https://blog.lyfegroup.com/hubfs/image-blog-solutions-maximizing-supply-chain-efficiency.jpg)](https://blog.lyfegroup.com/capscanadas-solutions-for-maximizing-supply-chain-efficiency) ### [Capsule Supply Solutions for Supply Chain Efficiency](https://blog.lyfegroup.com/capscanadas-solutions-for-maximizing-supply-chain-efficiency) In today’s highly competitive business environment, supply chain efficiency is crucial to success. A well-optimized... [Read More](https://blog.lyfegroup.com/capscanadas-solutions-for-maximizing-supply-chain-efficiency) [![](https://blog.lyfegroup.com/hubfs/unlocking_efficiency_with_the%20_capscanada_tamping_simulator_mobile.jpg)](https://blog.lyfegroup.com/optimize-capsule-filling-with-tamping-simulator-capscanada) ### [Optimize Capsule Filling with the CapsCanada Tamping Simulator](https://blog.lyfegroup.com/optimize-capsule-filling-with-tamping-simulator-capscanada) The Lyfe Group's tamping simulator is a leading-edge tool specifically designed to improve capsule filling processes... 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