Help.

I am from Canada and supply electrical residential panels to a modular (mobile) home manufacturer. We are having a slight problem with the total number of circuits available in a single panel. We use either a 200A service (max. 40 circuits) or 100A service (max. 30 circuits).

My client is telling me he doesn't have enough space available to handle all the circuits required. I can't believe that a modular (mobile) home could use more than 40 circuits. However, let's say he does need more than 40, I need to know how many dedicated circuits are required by NEC for a single family residence. Such as AFCI (varies with number of receptacles in bedrooms), fridges, microwaves, GFCI breakers in kitchens, garages, bathrooms, washers/dryers, stoves.

If we find that my client is correct, that he needs 40 + circuits are there any suggestions as to how to accommodate this? Pony panels, one safety switch feeding 2 panels?

I really appreciate your assistance and look forward to your replies.