This paper  presents a cost-effective method for fast and accurate in-line weighing of hard gelatin capsules based on the optimized capacitance sensor and real-time processing of the capsule capacitance profile resulting from 5000 capacitance measurements per second. First, the effect of the shape and size of the capacitive sensor on the sensitivity and stability of the measurements was investigated in order to optimize the performance of the system. The method was tested on two types of hard gelatin capsules weighing from 50 mg to 650 mg. The results showed that the capacitance profile was exceptionally well correlated with the capsule weight with the correlation coefficient exceeding 0.999. The mean precision of the measurements was in the range from 1 mg to 3 mg, depending on the size of the capsule and was significantly lower than the 5% weight tolerances usually used by the pharmaceutical industry.

Therefore, the method was found feasible for weighing pharmaceutical hard gelatin capsules as long as certain conditions are met regarding the Capsule filling machine and environment stability. The proposed measurement system can be calibrated by using only two or three sets of capsules with known weight. However, for most applications it is sufficient to use only empty and nominally filled capsules for calibration. Finally, a practical application of the proposed method showed that a single system is capable of weighing around 75 000 capsules per hour, while using multiple systems could easily increase the inspection rate to meet almost any requirements.