R&D Case Study: Migrating a Night Supplement from Capsule to Liquid Sachet Format
Background and Development Objective
A capsule-based night supplement was selected for format migration following a noticeable increase in market demand for ready-to-dissolve sachet systems. While the capsule format offered stability and dosage precision, the sachet format introduced a different set of functional and sensory expectations.
The R&D task assigned to the laboratory team was not simply to transfer the existing formulation into a liquid medium. The objective was to redesign the system in a way that would allow complete dissolution in a standard glass of water (approximately 150–200 ml), require only minimal spoon mixing, and provide acceptable sensory characteristics suitable for night-time use.
In addition to dissolution performance, the product had to overcome two inherent challenges typical of herbal extract-based formulations: strong botanical odour and naturally dark brown coloration.
The migration process therefore became a structural reformulation rather than a format conversion
In addition to dissolution performance, the product had to overcome two inherent challenges typical of herbal extract-based formulations: strong botanical odour and naturally dark brown coloration.
The migration process therefore became a structural reformulation rather than a format conversion
Laboratory Reformulation Phase
The development began with a detailed evaluation of the original capsule composition. Ingredients that function reliably in solid dosage systems do not automatically behave similarly in aqueous environments. Solubility characteristics, interaction with excipients and stability in solution required reassessment from first principles.
The laboratory team initiated controlled small-scale batch preparation, beginning with precise weighing of individual active components. Each ingredient was evaluated for its dissolution profile in water, observing sedimentation behaviour and potential phase separation.
Particular attention was given to herbal extracts. In capsule form, their inherent odour and colour remain enclosed and do not directly influence consumer perception. In liquid format, these characteristics become immediately evident. The extracts demonstrated strong aromatic notes and a natural brown hue typical of concentrated botanical materials.
At this stage, the team focused on three parallel objectives: improving solubility, masking herbal intensity and adjusting visual appearance.
At this stage, the team focused on three parallel objectives: improving solubility, masking herbal intensity and adjusting visual appearance.
Achieving rapid dissolution in 150–200 ml of water required careful adjustment of the formulation matrix. The target was a system that disperses uniformly with minimal spoon agitation, without visible clumping or persistent sediment.
Multiple internal trials were conducted to refine particle behaviour in water. The objective was not only dissolution, but also visual uniformity and absence of floating or settling fractions within typical consumer preparation time.
The final working prototype demonstrated stable dispersion under light manual mixing conditions, meeting the internal requirement of practical, user-friendly preparation
Dissolution Optimization
Sensory and Odour Masking Strategy
- The laboratory conducted iterative flavour adjustment cycles. Rather than introducing aggressive flavour systems, the objective was to create a mild and light sensory profile appropriate for night-time consumption. Over-flavouring was deliberately avoided to maintain product positioning.
- Masking strategies were evaluated alongside solubility behaviour to ensure that taste correction did not compromise dissolution performance.
The result was a balanced profile where herbal intensity was moderated while maintaining a subtle, non-invasive flavour character.
Colour Adjustment and Visual Presentation
Herbal extracts
typically introduce a dark brown tone in aqueous systems. For sachet-based consumer products, visual perception plays a significant role in perceived quality and acceptability.
Colour adjustment
During development, controlled colour adjustment was introduced to shift the appearance from a natural brown extract tone to a more neutral and consumer-friendly shade. The objective was not to disguise the product, but to create a visually coherent and stable appearance once dissolved.
Colour stability
Colour stability under short-term observation was also assessed to ensure uniformity during preparation.
Observations
from the R&D Phase
The migration from capsule to liquid sachet format revealed structural differences between solid and aqueous systems. Ingredients that are stable and inert in encapsulated form require new compatibility validation when introduced into a liquid environment.
Dissolution behaviour becomes a primary performance indicator. Sensory parameters move from secondary consideration to central formulation constraint. Visual presentation becomes part of functional quality.
The R&D phase demonstrated that dosage format migration is not a linear adaptation process. It is a comprehensive reformulation workflow requiring laboratory iteration, sensory balancing and practical usability validation.
Further scale-up considerations, including microbiological stability and industrial homogenization parameters, will be addressed in subsequent development stages.
The R&D phase demonstrated that dosage format migration is not a linear adaptation process. It is a comprehensive reformulation workflow requiring laboratory iteration, sensory balancing and practical usability validation.
Further scale-up considerations, including microbiological stability and industrial homogenization parameters, will be addressed in subsequent development stages.
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If you are considering dosage format migration — speak to us.
Contact BF‑EssE’s team for tailored support.
Contact BF‑EssE’s team for tailored support.
FAQ About Capsule to Liquid Sachet Migration
A formulation designed for encapsulation is optimized for solid-state stability and does not require dissolution behaviour in aqueous systems. When migrating to a liquid sachet format, solubility, sedimentation behaviour, taste perception and preservative compatibility must be reassessed. The process typically requires structural reformulation rather than simple ingredient transfer.
The primary risks include incomplete dissolution, phase separation, instability of active ingredients in solution, and sensory imbalance. Additionally, liquid systems introduce microbiological considerations that are not present in dry encapsulated products.
If the product must dissolve in 150–200 ml of water with minimal mixing, particle behaviour, excipient selection and flavour system must be carefully optimized. Poorly designed systems may lead to clumping, floating particles or sedimentation, negatively affecting user experience.
In capsule form, botanical extracts and actives are enclosed and bypass direct taste perception. In liquid format, even minor aromatic components become immediately detectable. Flavour balancing must therefore address bitterness, herbal odour and aftertaste without destabilizing the formulation.
Yes. Stability profiles in liquid systems differ significantly from solid dosage forms. Shelf-life validation, preservative efficacy and compatibility studies must be performed again during development.
Industrial scale parameters such as homogenization energy, filling precision and microbiological control should be considered early during R&D to avoid major reformulation during production transfer.