Waste Elimination linked to Automated filling weight adjustment of Dry Powder Inhaler
For more than 35 years, Dry Powder Inhaler manufacturing relied on manual filling weight adjustments to ensure each device met specifications. Although effective, this approach inevitably created systematic overfilling to safeguard dose accuracy. This long standing practice meant significant quantities of formulated substance were added unnecessarily—creating both material waste and environmental impact.
In 2024, our team transformed this process through a breakthrough automated filling weight adjustment system. By combining upgraded hardware, new in house software, and data driven control logic, the filling cells now continuously and automatically adjust the dose of every individual Dry Powder Inhaler. Rather than relying on periodic operator intervention, the system self optimises based on real time weight performance across recent units. This closes the loop on process control and ensures consistently precise filling across the entire production run.
This innovation eliminates the previous average overfill of 7 mg per device—equivalent to 560 kg of formulated material per year at current production volumes. This reduction delivers considerable cost savings and represents a major sustainability achievement: hundreds of kilograms of active material are no longer manufactured, handled, packaged, shipped, or ultimately unused in patient devices. The initiative directly supports our strategic goal to reduce waste and embeds sustainability by design in a core manufacturing step.
Beyond its environmental and cost benefits, the solution showcases true manufacturing innovation. Instead of replacing equipment, the team enhanced existing filling assets with intelligent automation, demonstrating how legacy processes can be radically modernised. The approach exemplifies smart factory principles—digitalisation, continuous feedback, and real time process control—resulting in a more stable, predictable, and quality assured operation.
This work stands out because it addresses a decades old industry challenge with imagination and technical creativity. It required close collaboration across engineering, operations, digital technology, and quality functions to ensure the solution met regulatory expectations while pushing the boundaries of what is possible on established production lines.
By elevating process capability, reducing waste, improving sustainability, and modernising an essential manufacturing step, this innovation gives our operations a clear competitive advantage. It embodies entrepreneurial thinking, lean improvement, and the drive to continuously deliver better outcomes for patients, the business, and the planet.
