capsule supplement manufacturer

Reputable manufacturers offer a wide range, including Hard Gelatin Capsules, Vegetarian/Vegan Hard Capsules (typically HPMC or Pullulan), Gelatin Softgels, and Vegetarian/Vegan Softgels. Many can also produce capsules with specific functionalities like Enteric-Coated (both hard and softgel), Delayed-Release (often using specific hard capsule shells or coatings), Chewable Softgels, and Twist-Off Softgels.

For Hard Capsules, the standard numerical sizes are available, most commonly #000, #00, #0, #1, #2, #3, #4, and #5. For Softgels, sizes are based on fill volume, typically measured in Minims or Cubic Centimeters (CC/mL), and come in various shapes (Oval, Oblong, Round, Tube, etc.). Manufacturers will have charts showing available sizes for both types.

Yes, manufacturers can produce capsule shells in a wide variety of custom colors and opacities (clear, translucent, opaque) using approved colorants. Printing services are also common, allowing you to print your brand logo, product name, or code directly onto the capsule shell using food-grade ink.

Hard capsules are primarily designed for dry fills including powders, granules, pellets, and mini-tablets. With specialized equipment and sealing methods, some hard capsules can also be filled with non-aqueous liquids or semi-solids.

Softgel capsules are specifically designed for liquid and semi-solid fills, such as oils, lipid-based solutions, suspensions, and pastes. They are not suitable for standard dry powders.

The exact weight of material a capsule can hold depends on the volume capacity of the capsule size and the density of your specific fill material. Manufacturers use charts and density calculations to determine how much of your unique formula will fit into a chosen capsule size. For softgels, capacity is typically defined by volume (Minims/CC) rather than weight due to the liquid fill.

Experienced manufacturers have technologies and formulation expertise to handle challenging fills, such as hygroscopic (moisture-absorbing) powders that can make hard capsules brittle (often managed with vegetarian capsules or specific fillers/packaging), or high-viscosity liquids that are difficult to fill into softgels.

Manufacturing facilities use automated high-speed filling machines with precise dosing mechanisms (e.g., dosators, tampers, pumps). In-process checks and statistical weight analysis are conducted throughout the production run to ensure that each capsule contains the correct, uniform amount of fill material within acceptable tolerances.

After the body is filled, automated capsule filling machines rejoin the cap to the body. Many modern machines apply a gentle locking mechanism during this process. For liquid-filled hard capsules, an additional step called "banding" or "sealing" is performed after filling and joining to create a tamper-evident, leak-proof seal around the seam.

Softgels are encapsulated and sealed simultaneously in a single process using rotary dies that apply heat and pressure to fuse the two shell ribbons together around the fill. Rigorous quality control checks, including visual inspection and physical testing, are performed to verify the integrity of this hermetic (airtight) seal and prevent leaks.

Many, but not all, capsule manufacturers have specialized equipment for filling hard capsules with non-aqueous liquids or semi-solids. This requires specific filling machinery and a post-filling sealing step (banding) to prevent leakage.

Manufacturers perform disintegration testing (measuring the time it takes for the capsule shell to break apart in a liquid medium) and dissolution testing (measuring how quickly the active ingredients are released and dissolve from the capsule) according to pharmacopeial standards relevant to the product and its intended release profile (standard, delayed, enteric).

Capsules undergo visual inspection (manual or automated) to check for physical defects such as inconsistencies in size, shape, color variations, foreign matter, damage (dents, cracks), and proper sealing/joining.

Yes, weight variation testing is a standard quality control measure. A sample of filled capsules from each batch is weighed to ensure that the fill weight is consistent across the batch and falls within acceptable regulatory tolerances.

Testing includes visual inspection for leaks or defects, and physical tests such as seam strength testing (measuring the force required to pull the seam apart) and often texture analysis to check shell firmness and elasticity, ensuring the shell is robust enough and the seal is intact.

Yes, MOQs are highly dependent on the capsule type (softgels often have higher MOQs than hard capsules), size (larger sizes might have lower unit counts per batch but still high MOQ by piece count), and the complexity of the fill or shell (e.g., custom colors, enteric coating, or challenging fills can influence MOQs). Custom formulations usually have higher MOQs than stock private label options.

Cost is influenced by the raw material cost of the shell (vegetarian shells are often more expensive than gelatin), the manufacturing complexity (softgels generally require more specialized equipment and process control than hard capsules), and the fill volume (larger capsules or denser fills mean fewer capsules needed per dose/bottle, impacting packaging costs).

Lead times vary based on the manufacturer's schedule, the complexity of the formula and capsule type, sourcing time for ingredients and packaging, and the current production load. They can range from a few weeks for standard private label hard capsules to several months for complex custom softgels or formulations requiring specialized testing or sourcing.

Common primary packaging options include plastic bottles (HDPE, PET), glass bottles, and blister packs (PVC/Aluminum). Some manufacturers also offer pouches or specialized unit-dose packaging.

Yes, manufacturers work with packaging suppliers to offer various child-resistant (CR) closure options for bottles and standard tamper-evident features like induction seals for bottles and the inherent sealing of blister packs and pouches.