Why Brands Choose Capsules
Six reasons capsules remain one of the most popular delivery formats in the supplement industry.
Cost-Effective Manufacturing
Capsules are usually more affordable to manufacture than gummies, softgels, stick packs, or liquids. Fewer flavoring systems, simpler packaging, and faster paths from concept to finished product.
No Sugar Required
Naturally sugar-free unless intentionally added. Ideal for keto, diabetic-friendly, longevity, weight management, and metabolic health formulas.
Vegan Options Available
HPMC and pullulan capsules offer plant-based positioning for clean-label, vegan, and premium wellness brands.
Multi-Ingredient Formulas
Capsules work well for complex blends — nootropics, immune support, beauty-from-within, stress and sleep, joint support, and herbal formulas.
Flexible Packaging
Bottles, jars, pouches, blister packs, sachets, stick-style daily packs, or bulk containers — ideal for retail, ecommerce, subscription, and clinical programs.
Consumer Familiar
Consumers already understand capsules. No taste or texture challenges. Easy to travel with and include in a daily routine.
Capsule Shell Types
Shell choice affects cost, consumer positioning, stability, and label claims.
Gelatin
Best for: General supplement formulas where animal-derived ingredients are acceptable.
Advantages
- ✓Cost-effective
- ✓Reliable machine performance
- ✓Familiar to consumers
- ✓Available in many sizes and colors
Considerations
- —Not vegan
- —Animal-derived
- —May not fit vegetarian, kosher, or halal positioning
HPMC Vegetarian
Best for: Vegan, vegetarian, clean-label, premium, or plant-based supplement brands.
Advantages
- ✓Vegan-friendly
- ✓Plant-derived
- ✓Good consumer perception
- ✓Lower moisture content than gelatin
Considerations
- —Usually more expensive than gelatin
- —May require different machine settings
- —Lead times can vary
Pullulan
Best for: Premium probiotics, beauty supplements, longevity products, and high-value formulas.
Advantages
- ✓Vegan-friendly
- ✓Premium appearance
- ✓Strong oxygen barrier
- ✓Good for sensitive ingredients
Considerations
- —Higher cost
- —Less common than gelatin or HPMC
- —May have longer sourcing lead times
Capsule Size Planning Guide
Capsules are sized by volume, not milligrams. Actual fill weight depends on powder bulk density.
| Size | Volume | Low Density 0.5 g/mL | Med Density 0.7 g/mL | High Density 1.0 g/mL | Common Use |
|---|---|---|---|---|---|
| Size 000 | 1.37 mL | ~685 mg | ~960 mg | ~1,370 mg | Large serving, less common |
| Size 00 | 0.90 mL | ~450 mg | ~630 mg | ~900 mg | Very common supplement size |
| Size 0 | 0.68 mL | ~340 mg | ~475 mg | ~680 mg | Common, easier to swallow |
| Size 1 | 0.50 mL | ~250 mg | ~350 mg | ~500 mg | Smaller serving formulas |
| Size 2 | 0.37 mL | ~185 mg | ~260 mg | ~370 mg | Smaller capsules |
| Size 3 | 0.30 mL | ~150 mg | ~210 mg | ~300 mg | Low-dose actives |
| Size 4 | 0.21 mL | ~105 mg | ~147 mg | ~210 mg | Pediatric, specialty |
| Size 5 | 0.13 mL | ~65 mg | ~91 mg | ~130 mg | Very small specialty |
Estimates only. Actual results depend on formula, powder density, flowability, particle size, compression behavior, machine type, and excipient system.
How Capsules Are Made
Our capsule manufacturing process follows a rigorous 8-step workflow to ensure accuracy, consistency, and quality.
Formula Review
We review active ingredients, serving size, target claims, density, flow properties, capsule type, and label requirements.
Raw Material Sourcing
Ingredients are sourced, documented, and checked for identity, quality, and compliance.
Milling & Screening
Powders are milled or screened for consistent particle sizes, improving blend uniformity and filling performance.
Blending
Active ingredients are blended with excipients. Each capsule must contain a consistent amount of active material.
Capsule Filling
Empty capsules are separated into cap and body. The body is filled with the powder blend, then the cap is joined.
Weight Checks
Capsule weight is monitored during production to ensure fill amounts stay within specification.
Polishing & Inspection
Finished capsules are cleaned, checked for defects, and prepared for packaging.
Packaging
Capsules can be packaged in bottles, jars, pouches, blister packs, sachets, or bulk containers.