Selecting the correct capsule size is essential for efficient production. It can help reduce waste, prevent fill errors, and keep your process running smoothly.
Vivion offers all standard hard gelatin capsule sizes: 000, 00, 0, 1, 2, 3, 4, and 5 (we also provide HPMC capsules and pullulan capsules). These sizes are compatible with most capsule filling machines used in commercial operations. Capsule sizing follows a reverse-numbering system in that the lower numbers indicate larger sizes. For example, size 000 is the largest capsule we stock, while size 5 is the smallest. We also offer elongated sizes 00E and 0E upon request.
To support your decision-making, we’ve developed an interactive chart showing detailed specifications for each capsule size we carry. You can select a capsule from the chart, and the corresponding size details will appear below.
Capsule Size Chart
Empty Capsule Size
Capsule Size
000
00E
00
0E
0
1
2
3
4
5
Empty Capsule Weight (Gelatin)
Average Weight (mg)
158
143
123
107
99
78
61
48
38
28
Tolerance
±10
±10
±7
±7
±6
±5
±4
±3
±3
±2
Empty Capsule Weight (Vegetarian)
Average Weight (mg)
163
152
136
107
105
79
63
50
40
30
Tolerance
±10
±10
±7
±7
±6
±5
±4
±3
±3
±2
Empty Capsule Volume Capacity (ml)
Capacity
1.37
1.00
0.90
0.78
0.68
0.48
0.36
0.27
0.20
0.13
Empty Capsule Weight Capacity by Formulation Density (mg)
Formulation Density
0.6 g/ml
822
600
540
468
408
288
216
162
120
78
0.8 g/ml
1096
800
720
624
544
384
288
216
160
104
1.0 g/ml
1370
1000
900
780
680
480
360
270
200
130
1.2 g/ml
1644
1200
1080
936
816
576
432
324
240
156
Empty Capsule Overall Closed Length
mm
26.1
25.3
23.4
23.5
21.6
19.4
17.6
15.7
14.3
11.1
Tolerance (mm)
±0.3
±0.3
±0.3
±0.3
±0.3
±0.3
±0.3
±0.3
±0.3
±0.4
Inches
1.029
0.906
0.921
0.909
0.85
0.764
0.693
0.618
0.563
0.437
Tolerance (inches)
±0.012
±0.012
±0.012
±0.012
±0.012
±0.012
±0.012
±0.012
±0.012
±0.016
Empty Capsule Individual Lengths (cap)
Cap (mm)
12.95
12.95
11.80
11.68
10.85
9.85
8.80
8.00
7.20
6.20
Tolerance (mm)
±0.35
±0.35
±0.35
±0.35
±0.35
±0.35
±0.35
±0.35
±0.35
±0.29
Cap (inches)
0.510
0.510
0.464
0.460
0.427
0.388
0.346
0.315
0.283
0.244
Tolerance (inches)
±0.014
±0.014
±0.014
±0.014
±0.014
±0.014
±0.014
±0.014
±0.014
±0.012
Empty Capsule Individual Lengths (body)
Body (mm)
22.20
22.20
20.22
20.19
18.35
16.40
15.15
13.45
12.10
9.30
Tolerance (mm)
±0.35
±0.35
±0.35
±0.35
±0.35
±0.35
±0.35
±0.35
±0.35
±0.29
Body (inches)
0.879
0.879
0.796
0.795
0.722
0.645
0.596
0.529
0.476
0.366
Tolerance (inches)
±0.014
±0.014
±0.014
±0.014
±0.014
±0.014
±0.014
±0.014
±0.014
±0.012
Empty Capsule External Diameter
Cap (mm)
9.91
8.58
8.56
7.65
7.64
6.96
6.39
5.85
5.33
4.91
Cap (inches)
0.390
0.338
0.337
0.301
0.301
0.274
0.252
0.230
0.210
0.193
Body (mm)
9.55
8.25
8.23
7.36
7.35
6.63
6.12
5.60
5.08
4.68
Body (inches)
0.376
0.322
0.289
0.29
Empty Capsule Quantity Per Case
Capsules per box
50,000
65,000
75,000
90,000
100,000
125,000
175,000
200,000
250,000
350,000
Capsule Sizing Terms You Should Know
Understanding capsule terminology helps ensure accurate planning, formulation, and machine setup. Below are key terms used in our capsule size chart and in capsule manufacturing:
Tolerance – The acceptable variation in capsule dimensions. Staying within tolerance is critical for machine compatibility and consistent output.
Individual Lengths – The length of the capsule body and cap measured separately in millimeters.
Overall Closed Length – The total length of the capsule once assembled, measured in millimeters.
Volume Capacity – The internal volume of the capsule, measured in milliliters. Useful when matching capsule size to fill volume.
Weight Capacity by Formulation – The estimated fill weight (in milligrams) based on the bulk density of your formulation.
Key Factors That Affect Capsule Size Selection
Selecting the right capsule starts with understanding your formulation. Its flowability, density, and compressibility all impact how it fills into a capsule. You’ll also need to consider the type of capsule material, such as gelatin or HPMC and pullulan, as different materials can affect performance and compatibility with your equipment. Finally, the dosage of your active ingredient plays a major role. The capsule must hold the required amount while still meeting regulatory and product requirements. Taking all these variables into account will help you choose a capsule size that works efficiently in production.
Capsule Type and Size Availability
When selecting a capsule, it’s important to know that some materials are only available in certain sizes. This can affect which capsule type makes the most sense for your product. If your formulation requires a specific capsule size, that may limit your material options. The table below outlines which sizes are available for each capsule type we supply, helping you make an informed decision based on both your formulation and production needs.
Formulation Volume
Your formula’s bulk density plays a key role in capsule selection. It affects how much material fits inside each capsule and can change the final dose. Depending on the density, you may need to adjust your capsule size, either by going larger or smaller than initially planned, to meet your target fill weight.
Product Consumer
Knowing who will be taking your capsule product is just as important as knowing what’s in it. Swallowability often influences capsule size. Larger sizes like 000, 00, and 0 are typically suitable for adults and large animals, while smaller sizes like 4 or 5 are better for children or smaller animals. Choosing the right size helps ensure ease of use and better compliance.
API Dose
The required dose of your active pharmaceutical ingredient (API) directly impacts capsule size selection. If the intended dose exceeds the capacity of your chosen capsule, you’ll need to either select a larger size or split the dose across multiple units.
Gelatin and HPMC capsules offer a wide range of size options to accommodate varying fill weights. For manufacturers using preservative-free, tapioca-based pullulan capsules, available sizes are typically limited to #00, #0, and #1, which are the most commonly used in commercial production.
Capsule Type
#000
#00
#0
#1
#2
#3
#4
#5
Gelatin
✔
✔
✔
✔
✔
✔
✔
✔
HMPC
✔
✔
✔
✔
✔
✔
✔
✔
Vegetable
✘
✔
✔
✔
✘
✘
✘
✘
Capsule Scale
To support size selection, the chart below provides a visual comparison of all capsule sizes. It shows the dimensions of each size in both millimeters and inches, giving you a clear reference for how each option scales in physical size.
Most Commonly Used Capsule Size
Sizes #0 and #00 are widely used in supplement manufacturing because they offer a good balance between fill capacity and ease of swallowing for most consumers. To help put their size into perspective, the chart below compares them to common coins.
The Numbers Behind Capsule Sizes
Higher numbers indicate smaller sizes in capsule sizing. For example, size #000 is the largest capsule Vivion offers, while size #5 is the smallest. This system is standard across the industry and important to keep in mind when planning your formulation.
Size 000
Commonly called “triple zero,” #000 capsules are the largest size of Vivion’s capsule range.
Volume: 1.27 ml
Overall length: 26.1 mm
External diameter of cap: 9.91 mm
Size 00
#00, or “double zero,” is the most commonly used capsule size for medicinal formulations and supplements.
Volume: 0.9 ml
Overall length: 23.4 mm
External diameter of cap: 8.56 mm
Size 0
#0 capsules are the second most popular size are #00 and are mainly used in pharmaceutical products and nutraceuticals.
Volume: 0.68 ml
Overall length: 21.6 mm
External diameter of cap: 7.64 mm
Size 1
#1 capsules are also commonly used, with just being slightly smaller than #0 capsules.
Volume: 0.48 ml
Overall length: 19.4 mm
External diameter of cap: 6.96 mm
Size 2
Although not as commonly used in food supplements, #2 capsules are popular in pharmaceutical manufacturing.
Volume: 0.36 ml
Overall length: 17.6 mm
External diameter of cap: 6.39 mm
Size 3
Because of their smaller overall volume, #3 capsules are used more in pharmaceutical manufacturing rather than food supplements.
Volume: 0.27 ml
Overall length: 15.7 mm
External diameter of cap: 5.58 mm
Size 4
The second smallest capsule size in Vivion’s capsule lineup, #4 capsules are uncommonly used outside of specialized medicinal applications.
Volume: 0.2 ml
Overall length: 14.3 mm
External diameter of cap: 5.33 mm
Size 5
The smallest capsule Vivion offers, #5 capsules are primarily used in pharmaceuticals.
Volume: 0.13 ml
Overall length: 11.1 mm
External diameter of cap: 4.91 mm
If you still aren’t sure which capsule size is right for your production, Vivion has a team of capsule experts waiting to support you. Contact one of our capsule experts today.
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