Capsugel® Zephyr™

Dry-Powder Inhalation Capsule Portfolio

Dry-powder inhalation (DPI) technology offers a favorable drug development opportunity for respiratory or systemic drug delivery. Delivering a uniform dose in a portable, easy-to-use system, capsule-based DPI devices are a simple and cost-effective way to deliver inhalable medication.

Capsugel® Zephyr™ is Lonza’s customizable dry-powder inhalation capsule portfolio that is optimized to provide superior performance and compatibility between the capsule/device and capsule/formulation.

Our dry-powder inhalation capsule portfolio offers:

  • Consistent powder release
  • A customized approach to optimize performance of the end product
  • Compatibility with a large selection of device principles and opening systems
  • Ideal puncturing and cutting performance
  • Availability in gelatin (Coni-Snap® Gelatin or Coni-Snap® Gelatin PEG) and HPMC (Vcaps® or Vcaps® Plus) capsules
  • R&D and regulatory support throughout the development including QbD approach


Lonza partners with its customers to closely match specific requirements and leverages a wide range of customization services for its DPI capsule portfolio. To ensure optimal performance for the required device, Lonza:

  • Adheres to strict microbial limits to comply with all major DPI regulatory guidelines globally
  • Applies strict manufacturing conditions and In Process Controls to achieve consistency in dose delivery to the patient
  • Selects and modifies the final capsule to the desired stability and custom weight tolerances for low-dose APIs
  • Recommends capsules to optimize puncturing and cutting performance
  • Provides a variety of options for capsule branding
  • Offers a secure supply chain, including packaging, to maintain integrity of low-moisture compounds

Given patient convenience and compatibility with a range of formulations and doses, capsule-based dry-powder inhalation (DPI) technology is becoming the specialists preferred DPI drug delivery platform for respiratory and systemic applications.



At Lonza, we provide expertise in spray dry processing and jet-milling for optimized particle engineering – which is crucial to successful respiratory product design. Lonza has facilities that are recognized for spray-dried dispersion technology and particle engineering with fast-track programs for new chemical entities. From common to very complex inhalation development, our scientists can select a lactose-free, spray-dried dispersion-based approach based on the API characteristics and target product profile – from large to small molecules. 

The Capsugel® brand offers more than 20 years experience and billions of capsules delivered for inhaled drug delivery systems. The Capsugel® portfolio of DPI capsules is well known for its world-class quality that helps ensure dose uniformity and reproducibility, as well as high-performance machinability. 

We have developed customized capsule solutions for a number of drugs that have become the gold standard in the treatment of major respiratory diseases. Global supply chain, security of supply and technical and regulatory support accompany every capsule sold. Customized DPI capsules and encapsulation are core competencies, with dedicated equipment in place for efficient, phase-appropriate capsule filling.

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