Client: Premium European nutrition brand (confidential)
Project Type: CDMO development of a multi-active capsule formulation
Capsule Format: Size 00, two capsules per day
Project Requirements
A premium European nutrition brand wanted to develop a multi-active NMN capsule formula for its longevity supplement range. The challenge was to fit the target doses into just two Size 00 capsules per day while meeting the brand’s clean-label expectations and cost targets.
| Requirement | Project Specification |
|---|
| Daily serving | Incorporate all target active ingredients into two Size 00 capsules per day. |
| Product positioning | Meet clean-label requirements consistent with the brand’s premium positioning. |
| Manufacturing cost | Control manufacturing costs and achieve commercially competitive pricing. |
| Formulation challenge | Accommodate high active loads, including fat-soluble and sensitive ingredients, within limited capsule space while addressing stability requirements. |
The project focused on formulation development rather than anti-aging efficacy claims. Its central objective was to determine how multiple active ingredients could be efficiently and stably incorporated into a daily serving of two Size 00 capsules.
Scope of Services
OriginBio supported the development process from target active doses to a formulation proposal ready for quotation.
Raw Material Input Calculations
Using the client’s target doses and the potency of each raw material, OriginBio calculated the actual weight required for each ingredient. These calculations provided the foundation for designing the active ingredient layers and coating systems.
Pellet Core and Coating Assessment
OriginBio evaluated pellet core types, active ingredient layers, binders and coating excipients. Particular attention was given to the stability requirements of fat-soluble and sensitive active ingredients.
Size 00 Capsule Fill Feasibility
OriginBio calculated the total capsule fill requirements, accounting for the pellet cores, binders and coatings as well as the active ingredients.
The assessment considered fill density, processing constraints and stability risks to determine whether Size 00 capsules could accommodate the target doses within the two-capsule daily serving.
Parallel Evaluation of Three Pellet Manufacturing Routes
To address the high active-loading requirements, OriginBio evaluated three candidate pellet manufacturing routes in parallel. This gave the project several processing options rather than relying on a single microencapsulation technology.
| Manufacturing Route | Main Advantage | Development Consideration |
|---|
| Active layering onto microcrystalline cellulose (MCC) cores | Established core structure with good mechanical strength | The cores occupy part of the available capsule fill capacity. |
| Coreless MCC extrusion-spheronization | Potential to achieve a higher proportion of active ingredients | Pellet formation and process compatibility require assessment. |
| Active layering onto starch cores | Can accommodate specific clean-label excipient preferences | Pellet hardness, coating performance and stability require verification. |
Cost Optimization
OriginBio reviewed the combination of branded ingredients, active ingredient concentrations, raw material specifications and capsule types to identify opportunities to reduce manufacturing costs.
The objective was to improve pricing competitiveness while maintaining the target doses and meeting the brand’s clean-label requirements.
Completed Deliverables
Formulation Assessment and Raw Material Selection
Completed the compatibility and formulation feasibility assessment for the multiple active ingredients and confirmed the raw material specifications.
Evaluation of Three Pellet Manufacturing Routes
Compared the advantages, limitations and development risks of MCC core layering, extrusion-spheronization and starch core layering.
Capsule Fill Calculations and Feasibility Assessment
Completed the calculations translating target active doses into actual fill requirements for Size 00 capsules, including the contribution of pellet cores, binders and coatings.
Cost Optimization Proposal
Completed one round of quotation optimization, achieving a 21% reduction in manufacturing costs through raw material sourcing and formulation redesign.
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