2025 Predictions: Industry Leaders Weigh in on the Future of Oral Solid Dose

New year, new advancements for the industry’s oldest and most beloved dosage form? It’s likely, according to experts. Not surprisingly, industry leaders predict a continued focus on improved adherence via user-friendly dosage forms and designs in both the pharma and nutraceutical spaces. Users want delivery formats that not only work with their lifestyles but are enjoyable. As Juliana Erickson, global product innovation manager for Lonza Capsules & Health Ingredients puts it, look for a “prioritization of pleasure” in 2025. 

Technology will also be key to OSD’s future, with advancements in automation, continuous manufacturing and 3D printing helping manufacturers respond to shifting patient demographics and needs. Better equipment efficiency and accuracy will enable manufacturers to stay on top of necessary cost-saving initiatives. 

Quality will remain ever-important, as manufacturers continue to wrestle with nitrosamine impurities. On the nutraceuticals side, manufacturers will square off against pharma-level accountability and requirements. And 2025 may be the year that OSD gets in on the weight-loss market frenzy, as new innovations enable manufacturers to overcome bioavailability challenges of oral biologics.

Here’s a look at what industry leaders in pharmaceuticals and nutraceuticals are predicting for the coming year.

Patient/Consumer-Friendly Delivery Formats 

Expect a patient-focused and technologically sophisticated future 
The OSD landscape is set to witness transformative advancements in 2025 and beyond. High-potency drugs, driven by oncology and specialized therapies, will continue to dominate development pipelines. This highlights a critical shift toward addressing complex and niche diseases. Despite challenges in bioavailability and stability, ongoing innovations in oral formulations for obesity treatments promise expanded access and adherence for patients. 

Additionally, 3D printing technology will redefine what is possible in OSD. From multidrug tablets to customized release profiles, 3D printing offers unparalleled flexibility, paving the way for personalized medicine. Finally, patientcentric dosage forms will continue to gain prominence. Innovations such as sprinkle formulations, orally disintegrating tablets, and transformative dosage forms will ensure better adherence for diverse patient populations, including pediatric and geriatric groups. Dosage forms that prioritize flexibility, convenience and accuracy will play a pivotal role in improving patient quality of life. As we enter 2025, these trends underscore a patient-focused and technologically sophisticated future for OSD. 
• Tom Sellig, CEO, Adare Pharma Solutions

Patient-centric designs will drive better outcomes 
Better understanding of disease mechanisms has helped bring new therapies to market, but in 2025 and beyond, more active participation of patients is required to achieve safe and effective drug regimens. Up to 30% of U.S. healthcare spending is wasted due to poor patient adherence. Product design improvements that lead to better adherence can improve outcomes and potentially save billions in health care costs. With patient usage issues such as multi-morbidity, incorporating patient-centric dosage form design concepts can add value to the product early on. Product design teams must comprehensively assess patient characteristics such as disease conditions, disabilities, impairments and specific needs, and incorporate those factors early into product development. 

To enhance compliance, we at BioDuro see increasing adoption of oral modified-release formulations in early development, particularly for high-dosing frequency drugs. From a business perspective, incorporating patient-centric design allows companies to differentiate themselves from the competition and make products more desirable. 
• Bhavishya Mittal, Ph.D., VP, Product Development and Manufacturing, BioDuro 

Development will focus on safety, convenience and compliance 
Patient-centric innovation focused on safety, convenience and compliance, will shape the future of drug development. In view of safety, nitrosamine risk mitigation strategies are necessary for potential reformulations and new drug formulation to comply with updated guidelines. Here, ascorbic acid and other nitrite scavengers have demonstrated their role as functional excipients, reducing nitrosamine formation by blocking nitrosation reactions. With growing pill fatigue, polypharmacy, and over 60% of APIs being inherently bitter, the demand for more patient-friendly dosage forms that support compliance and accommodate multi-API combinations, is on the rise too. Flavoring agents, including maskers and bitterness blockers, have become an essential tool in pharmaceutical formulation to improve the palatability of medicines. Additionally, formulations that enable higher drug loading and optimized bioavailability could help lower dosage frequency and minimize adverse events, helping patients adhere to their prescribed treatments. This would be revolutionary in the case of cannabidiol-based medications for instance.
• Céline Zuber, Manager, Global Marketing and Communications, Health, Nutrition & Care, dsm-firmenich 

Consumers will seek a more enjoyable supplement experience 
Consumers are demanding more from nutraceutical supplements than efficacy alone — they are seeking enjoyable and experiential delivery formats that elevate their daily routines. Lonza’s proprietary research reveals 70% are willing to pay more for a more enjoyable, memorable supplement experience. This aligns to a key trend for 2025: the prioritization of pleasure. 

Going beyond a product’s ingredients to captivate consumers through scents and flavors is one way that brands can meet consumer needs and stay ahead of the competition. Next-generation capsules enable the creation of multi-sensory experiences associated with consumers’ holistic health. By combining exceptional delivery systems with scented supplements, brands can develop truly holistic products that bridge the gap between sensory perception and nutritional supplements. This 360-degree experience unlocks a new frontier in supplement innovation, catering to a wider range of consumers — particularly those seeking a more enjoyable and engaging approach to wellness.
• Juliana Erickson, Global Product Innovation Manager, Lonza Capsules & Health Ingredients 

Patient-centricity and sustainability will intersect 
Patient-centric considerations, such as improving ease of use, adherence, and overall user experience remain the main forces shaping the future of oral dosage forms. That being said, environmental concerns are becoming increasingly influential as regulators and end users push brands to adopt greener, more responsible drug manufacturing practices. 

There’s an opportunity here for producers to improve their environmental credentials through the adoption of biodegradable and renewable plant-derived polymer excipients in place of synthetic materials. Modified starches, for example, are not only kinder to the environment, but are paving the way for more effective drug delivery systems through the creation of smaller, easier-to-swallow pills. Implementing streamlined production processes, like continuous manufacturing, can also help minimize waste and energy consumption and maintain product quality, safety and efficacy. In 2025, expect to see the pharma industry work to embrace this dual challenge of prioritizing sustainability, while ensuring patient needs are kept front and center. 
• Ketaki Patwardhan, Global Technical Developer, Roquette 

Look for safer, more efficient, personalized and advanced treatment options 
Oral solid dosages are projected to grow steadily in 2025 and beyond, given ease of administration and increased patient compliance. Increasing population and longer lifespans contribute to this growth. The following trends are expected to shape the ongoing evolution of OSD toward safer, more efficient, personalized and advanced treatment options for patients: Oral delivery of macromolecules and biologics, including orally ingestible devices and long-acting OSD are gaining momentum as innovative platforms; Increased adoption of digitalization and data driven approaches, including AI for discovery, formulation, manufacturing and clinical trials — which all lead to accelerated drug development; Enhancement of solubility and bioavailability of poorly soluble drugs remains an area of focus, with novel technologies to address the unmet needs; Continuous manufacturing and additive manufacturing, along with precision medicine, continue to bring innovation into the industry; Greater emphasis on sustainable manufacturing practices reduces environmental impact.
• Shahrzad Missaghi, Ph.D., Senior Manager, Product Development, Colorcon 

Technology and Equipment 

Tablet compression technology will see advances in efficiency, simulation and containment 
In the tablet compression technology segment, there will likely be three main areas of focus for the coming year. First, a continued emphasis on operational efficiency, and specifically employing fast-changeover strategies that leverage the use of exchangeable turrets, die table segments, and fastchange product contact parts. For best-in-class equipment, a full change in less than four hours is being achieved on a consistent basis. 

Second, compaction simulators will continue to gain in popularity to drive streamlined material characterization, product development, process optimization and predictive scale-up. Finally, the trend toward equipment containment solutions and minimizing or eliminating PPE will continue, as both dry and wash-in-place containment technologies gain favor. Full containment systems, featuring the tablet press and all related peripherals, will be deployed at the development, scale-up, and production stages. 
• Frederick Murray, President, KORSCH America 

3D printing will revolutionize OSD delivery
3D printing is poised to revolutionize oral solid drug delivery systems, bringing precision, personalization and innovation to the forefront of pharmaceutical development. This technology meets the growing demand for customized therapies, enabling tailored doses, intricate geometries, and advanced drug-release profiles. Notably, it facilitates the delivery of highly potent drugs, such as anti-cancer treatments, by balancing efficacy with minimized toxicity. 3D printing also enables the production of polypills, combining multiple active ingredients into a single dosage form, improving adherence and outcomes for chronic disease patients. By supporting controlled, delayed, and immediate drug-release mechanisms, this technology optimizes treatment regimens. As regulatory bodies adapt to these advancements, 3D printing will reshape the future of oral solid delivery systems, offering more personalized, efficient and patient-centric health care solutions.
• Jnanadeva Bhat, Ph.D., Vice President, Head – Formulation R&D Pharma and Nutra, ACG

Industry will shift towards sourcing equipment from system providers 
Today, the OSD form holds more than 50% of the pharmaceutical market share and is predicted to remain constant in the coming years. One reason is good shelf life offered through solid dose, compared to liquid forms. Another reason is excellent homogeneity in the mixing of active ingredients, either inside the tablet or via tablet coating, is achievable and replicable. A significant shift is occurring towards sourcing equipment from system providers, benefiting manufacturers by reducing supplier handling and facilitating faster, more structured plant installations and easier integration. Continuous manufacturing and PAT technology will remain important for their advantages, while batch production will continue to be a flexible and proven process in future manufacturing.
• Jessica Kyereme-Flaspöhler, Ph.D., Marketing Manager, DIOSNA Dierks & Söhne GmbH 

Tech advancements will help drug producers respond to patient demographic shifts 
Advancing technology and evolving patient needs are coming together to mold the future of oral dosage forms. Continuous manufacturing and automation, for instance, have the potential to revolutionize production methods, offering unparalleled efficiency, consistency and scalability. The adoption of 3D printing in pharmaceutical applications could also usher in a new era of accuracy and personalization, enabling the creation of highly customized medicines virtually on demand. 

These advancements can equally help drug producers respond to the demographic shifts shaping the industry, namely an aging population in many key markets and growing demand for pediatric-friendly formulations. For elderly end users, the headline benefits are improved access to easy-to-swallow formats and controlled release systems that reduce the need for polypharmacy. In children’s medicine, palatable solutions, like chewable or orodispersible tablets, will help address the longstanding challenge of adapting adult medications, unlocking safer, easier-to-take treatments for the youngest and most vulnerable patients served by our industry. 
• Stephen Flynn, Global Market Manager, Oral Dosage, Roquette 

Manufacturers will look for flexible, economical solutions 
When it comes to solids in the pharma, nutraceutical and food industries, we experience a great demand for solutions that make processing more flexible and economical — this applies to both small batch sizes, e.g. for laboratories or compounding pharmacies, and industrial production scales for global players. In the field of granulation and tablet coating, for example, two innovative technologies are attracting a great deal of interest. One is the hotmelt process with fluid bed processors, as it greatly reduces process times and thus significantly lowers production costs. The second is a new generation of tablet coaters with an exceptionally high batch size range of 10% to 100% using one drum and a very high degree of automation, which eliminates the need for manual intervention. This results in consistently high product quality and a substantial reduction in process times and spray liquid consumption.
• Sabri Demirel, Managing Director, Romaco North America 

Manufacturers will seek out all-in-one solutions 
Companies in the pharma, nutraceutical and food industries are increasingly looking less for individual machines or machinery components but more for complete lines and all-in-one solutions, as they offer several advantages. The most important of these include reducing complexity by having fewer partners to coordinate, greater efficiency in implementation and, finally, greater sustainability, both in financial and environmental terms. In our experience, the basis for such comprehensive solutions is a combination of two things: advanced automation that guarantees the highest product quality while reducing material consumption, and end-to-end service concepts. They complement the innovative technology by extending the service life of the machines, providing local expertise and enabling fast and effective support across all distances thanks to state-of-the-art digital service tools. This not only ensures cost efficiency and excellent OEE, but also overall sustainability.
• Bill Crozier, Sales Director, Romaco North America Inc. 

Scientists will leverage technology to optimize product development
In 2025, advancements in manufacturing technology and polymer science are revolutionizing the capsule industry, driving the widespread adoption of cellulose-based capsules. These innovations address raw material concerns, enhance API release and stability, and offer formulators significant advantages. As the limitations of gelatin become increasingly evident, scientists are leveraging modern technologies to optimize product development and adapt to shifting market demands.

The adoption of cellulose capsules continues to grow significantly. While costs may pose challenges, the industry's focus on rapid market entry and first-time-right development underscores the advantages of vegetarian alternatives. Global supply chain stability and environmental sustainability remain top priorities. Coupled with instability in the capsule manufacturing market, these factors highlight the risks of relying solely on traditional brands. Securing a sustainable capsule supply has never been more critical in navigating these evolving challenges.
• Subhashis Chakraborty, Ph.D., General Manager, Head - Global Product Management, ACG Capsules, ACG

Quality 

Supplement manufacturers will face pharma-grade quality requirements 
Consumer protection groups verify whether supplement-containing softgels open and release as advertised. Often, certain types of reactive fills and extreme storage conditions result in crosslinking, which may negatively impact fill release. Concurrently, popularity is increasing for the fast and reliable release of active ingredients, especially in analgesics, sleep aids, allergy remedies, cough and cold formulas, and indigestion treatments. Consequently, manufacturers are pressured to produce products that meet the stringent requirements of pharma regulations and advocacy groups that include defined release profiles and dissolution properties. As gelatin is a foundational component of softgels, this industry has responded by developing special grades of pharmaceutical gelatin tailored to the specific requirements of supplement, OTC and Rx brands.
• Angie Rimel, Marketing Communications Manager, North American, GELITA 

Manufacturers will look for solutions to mitigate nitrosamines risk 
The presence of nitrosamine impurities in pharmaceuticals has been a pivotal issue in recent years, and we expect this to continue to come under the spotlight in 2025. Nitrosamines are typically obtained through nitrosation reactions, where secondary amines react with nitrosating agents like nitrous acid or its derivatives. Common solvents used in these reactions include dichloromethane, acetic acid and ethanol. These reactions are particularly concerning due to the potential formation of carcinogens. As producers become more aware of the impact — both medical and financial — of nitrosamine impurities, it’s time solvents got the attention they deserve. Solvent-free manufacturing processes that mitigate this risk and enhance the safety of ingredients used in pharmaceuticals will become a valuable option.
• Álvaro Nocete, Division Business Manager – Pharmaceuticals, HTBA 

Partnerships 

Industry trends will lead to collaborative efforts 
Several trends are likely to arise or accelerate in 2025 across the OSD segment. The push for speed to market in drug approvals will continue, supported by expedited R&D timelines and fast-tracked approvals for OSD products meeting unmet or underserviced therapeutic needs. Technology also will continue its march in the areas of smart manufacturing and packaging. Advancements in these segments will further enable automation, continuous manufacturing and the use of AI, driving the overall digital transformation movement. 

From PCI’s position as a CDMO, we’re seeing much of these trends point toward expanded partnerships and collaborative efforts. Several factors, including the complexity and cost of specialized equipment and the integration of digital technology, inherently lend themselves to forming such strategic partnerships — and the data supports this. The OSD contract manufacturing market was valued at $35.6 billion in 2023 and is anticipated to grow at a CAGR of 5.6% now through 2032. Much of this uptick will be steered by particularly complex OSD formulations, including specialist high-potency drugs and novel drug delivery systems, with oncology claiming a large slice of this pie. 
• Rebecca Coutts, Senior Director of Pharmaceutical Development, PCI Pharma Services 

Small biotech innovators will seek trusted partners 
The 2025 OSD landscape will be shaped by evolving dynamics between small biotech companies and their CDMO partners. As smaller biotech innovators increasingly outsource drug development, they face challenges like the complexities of ‘beyond Rule of 5’ drug substances and the need for enabling technologies that demand specialized expertise. More clinical programs will turn to tried and tested patient-centric solutions that drive better scientific outcomes at lower cost against an increasingly costly regulatory environment. But is it realistic to expect that small biotechs will have all the expertise to navigate through all these issues? This is why we at Catalent foresee an increasing need for a trusted partner to bring a wealth of drug product development and manufacturing expertise, who can support small biotechs in de-risking their assets through scientific advice in a more consultative business model.
• Stephen Tindal, Director, Scientific Advisory, Oral Small Molecules, Catalent 

Ingredient Innovation 

Advancements in excipients are needed to meet the challenges of oral biologics 
The rising prominence of biologics and new chemical entities is fundamentally reshaping the oral dosage landscape. These complex molecules, including peptides and protein-based APIs, often bring with them challenges, such as poor stability and limited absorption, when formulated for oral delivery. Developing next-generation excipients that meet strict safety and efficacy standards has therefore become a critical focus. Innovations in the use of ingredients like cyclodextrins, lipid-based systems and multifunctional carriers are paving the way for more effective drug formulations. These excipients enhance solubility, protect sensitive active ingredients and optimize bioavailability, allowing formulators to deliver therapies that were once deemed unfeasible, and make existing treatments more effective and efficient. As the boundaries of drug design expand, these advancements are becoming essential to meet the needs of an increasingly diverse and complex pharmaceutical portfolio and patient landscape.
• Talles Ernica, Global Technical Developer, Roquette 

Innovative formats of OSD supplements will help manufacturers stand out
In 2025, bioavailability will be a key focus, especially in OSD formats like omega-3 supplements. Not only does high bioavailability enhance nutrient absorption, unlocking greater health benefits such as brain, heart, joint, and eye health from EPA and DHA fatty acids, but it subsequently allows formulators to tap into consumer demand for better sensory properties and ease of swallowing. Recent advances in omega-3 purification and processing technologies mean it’s now possible to develop monoglyceride (MAG) form ingredients. This unique form offers up to three times higher absorption efficiency of traditional omega-3 formats, making it ideal for low-dose, highly effective OSD supplements. Innovative formats of omega-3 fatty acids, like the MAG form, are poised to drive the future of omega-3 supplementation by enabling effective, appealing OSD formats that will help supplement manufacturers stand out in the market and better meet consumer needs.
• Rubén Medina, Chief Commercial Officer, Solutex 

The industry will advance toward ethical and scientifically-backed formulations
As we look to 2025, nutraceutical oral solid delivery systems are being redefined by two transformative forces: the rise of clean-label, sustainable formulations and the growing demand for clinically validated branded ingredients. Consumers now prioritize products free from artificial additives and expect high-quality, traceable ingredients in tablets, capsules, and soft gels. Transparency and ethical sourcing have become non-negotiables, helping brands build trust and stand out. This trend aligns with stricter regulatory standards from bodies like the FDA and EFSA, which encourage natural ingredient use and greater transparency. Simultaneously, branded ingredients supported by robust clinical evidence are revolutionizing key health categories, such as immune support and cognitive health. As consumer expectations and regulatory demands converge, the industry is advancing toward a future of innovative, ethical, and scientifically backed formulations.
• Manali Dalvi, Lead Research and Development, ACG Capsules, ACG

Market Trends 

Innovation and training will help the industry meet cost-saving challenges 
Oral solid dose is the most efficient dosage form related to manufacturing, packaging, distribution and administration. Hence, the market will remain strong, and solid oral dose will be preferred over competitive drug delivery systems. My forecast for 2025 is that the industry will be challenged with cost-saving initiatives related to drug development and more efficient manufacturing processes. Innovation and training will be at the forefront in 2025 to meet those challenges. Smaller regional manufacturers tend to be more flexible when implementing these changes, whereas larger multinational companies are more rigid and typically charter through layers of bureaucracy to make a change. Larger companies with multiple manufacturing sites will focus on unified SOPs, work instructions, and, most importantly, training to optimize operational efficiency relating to cost savings throughout the corporation.
• Dale Natoli, President and CEO, Natoli Engineering 

We will see a resurgence of the OSD sector 
The pharma OSD sector has been sluggish for several years, with much of the industry’s emphasis/investments going to the cell and gene therapy, ATMPs and fill-finish sectors. The pendulum has however recently begun to swing. In 2025, I believe we will see the continued resurgence of the OSD sector, both for new products to market as well as the increased need for manufacturing capability for existing products. One specific area of note is oral GLP-1s. The GLP-1 market has exploded and its potential is estimated to be over $150 billion in the next decade. The main delivery mechanism today is via needle injection, least preferred by patients. Several oral forms (most preferred) are in late phase trials and will be game changers. Novo Nordisk and Eli Lilly are the most prominent players in this market, but supply shortages will allow others to gain market share.
• Dave DiProspero, Senior Fellow and Senior Associate, CRB 

Oral hormone receptor agonists will hit the market 
In 2025, I see a strong industry move toward producing hormone receptor agonists, such as GLP-1 agonists for diabetes and weight loss, in solid dosage form. Reports show that 12% of Americans have taken a GLP-1 and 6% are currently using them. I can see with this type of volume a move away from weekly injections and towards a daily or weekly tablet. This would benefit both the user and the producer with a better customer experience and lower production costs. I’m aware of a few large pharma companies already researching it and a number of compounding pharmacies that already have products on the market.
• Alastair Sanderson, CEO, Stokes Tablet Presses

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