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.
| 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 |
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.
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.
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.
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.
| Capsule Type | #000 | #00 | #0 | #1 | #2 | #3 | #4 | #5 |
|---|---|---|---|---|---|---|---|---|
| Gelatin | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ |
| HMPC | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ | ✔ |
| Vegetable | ✘ | ✔ | ✔ | ✔ | ✘ | ✘ | ✘ | ✘ |
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.
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.
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.
Commonly called “triple zero,” #000 capsules are the largest size of Vivion’s capsule range.
#00, or “double zero,” is the most commonly used capsule size for medicinal formulations and supplements.
#0 capsules are the second most popular size are #00 and are mainly used in pharmaceutical products and nutraceuticals.
#1 capsules are also commonly used, with just being slightly smaller than #0 capsules.
Although not as commonly used in food supplements, #2 capsules are popular in pharmaceutical manufacturing.
Because of their smaller overall volume, #3 capsules are used more in pharmaceutical manufacturing rather than food supplements.
The second smallest capsule size in Vivion’s capsule lineup, #4 capsules are uncommonly used outside of specialized medicinal applications.
The smallest capsule Vivion offers, #5 capsules are primarily used in pharmaceuticals.
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.