Capsule Size Guide for Manufacturers

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:

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

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

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

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

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.

Capsule Scale Chart

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.

Most Commonly Used Capsule Size

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.

Image of capsule size 000 holds about 1000 mg.

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
Image of capsule size 00 holds about 730-735 mg.

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
Image of capsule size 0 holds about 500 mg.

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
Image of capsule size 1 holds about 400 mg.

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
Image of capsule size 2 holds about 300 mg.

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
Image of capsule size 3 holds about 200 mg.

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
Image of capsule size 4 holds about 95-210 mg.

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
Image of capsule size 5 holds about 60-130 mg.

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.