(M1030-11-61) Capsule Customization: Pioneering Automated Production of Patient-Specific Poly-Pills

Purpose: This study addresses the complex issue of polypharmacy, which is the concurrent use of multiple medications, a scenario common specifically for elderly individuals [1]. The challenge leads to medication non-adherence, resulting in substantial economic costs estimated at $200 billion annually in the US and €125 billion in the EU [2, 3]. We present a pioneering automated technology designed to facilitate the production of personalized poly-pills using mini-tablets in capsules, aiming to enhance adherence and reduce economic burdens.

Methods: The methodology utilizes precise automation for compounding mini-tablets into hard gelatin capsules. This automated process is tailored to minimize the number of dosage forms and customize doses of Active Pharmaceutical Ingredients (APIs) according to individual patient needs. The system incorporates vibration dispensers equipped with optical counters for high precision, and an integrated conveying system forms a complex assembly capable of continuous, efficient combined capsule production.

Results: The lab-scale automated system demonstrated effective capability in compounding diverse types of mini-tablets into capsules at a rate of approximately 300 capsules per hour. This system allows for the flexible and continuous production of small, patient-specific batches of capsules, with the ability to dynamically adjust the mini-tablet composition inside the capsules in subsequent batches. A patent application was filed to protect this technology.

Conclusion: The developed technology showcases significant potential in improving medication adherence by facilitating the precise and efficient compounding of mini-tablets into capsules. While it has not been directly tested for its impact on adherence, its ability to enable scalable production of customized poly-pills suggests that it could help reduce the complexity of medication regimens. This, in turn, might lead to improved adherence among patients, based on existing data on medication management challenges. This advancement represents a step forward in the field of personalized medicine, emphasizing a patient-centric approach to pharmaceutical production.

References: 1. Ryan TP, et al.; Medication adherence, medical record accuracy, and medication exposure in real-world patients using comprehensive medication monitoring. PLoS One. 2017 Sep 28;12(9).
2. European Council Policy makers Debate. An EU response to medication non-adherence. Brussels, 2010.
3. Viswanathan M, et al.; Interventions to improve adherence to self-administered medications for chronic diseases in the United States: a systematic review. Ann Intern Med. 2012 Dec 4;157(11):785-95

Acknowledgements: Gratitude is expressed for the support provided by the European Union through the "Operational Programme Jan Amos Komenský (OP JAK)". This work has been supported under the project "New Technologies for Translational Research in Pharmaceutical Sciences (NETPHARM)", registration number CZ.02.01.01/00/22_008/0004607.


Figure 1. Dispensing station (on the left) and linear compounding section composed of dispensing stations (on the right)


Figure 2. Physical demo-device of the automatic compounding section


Figure 3. Compounding of mini-tablets into the hard gelatine capsules