With their unique properties and advantages over more traditional options such as gelatin capsules, pullulan capsules are gaining popularity in the supplement manufacturing industry. These plant-based capsules have oxygen barrier protection, making them perfect for encapsulating sensitive active ingredients. They also originate from a completely natural source, increasing their appeal to the growing number of consumers who are becoming more conscious of what they put into their bodies. Pullulan capsules are also odorless, tasteless, and easy to digest and are rapidly becoming a preferred alternative to the synthetic HPMC capsules.1
This guide aims to help manufacturers understand the benefits, applications, and best practices for working with pullulan capsules, ensuring they make informed decisions when selecting capsule options best suited for their product formulations as well as their consumer base.
Pullulan is a polysaccharide polymer made from the starch of the fungus Aureobasidium pullulans. The reported first mention of its existence was in 1938, and in 1976 the Hayashibara Company began commercial production of pullulan.2 Because pullulan as a polymer is water-soluble, tasteless, and odorless with film-forming properties, it serves as an ideal material for manufacturing with capsules.
Pullulan capsules can be used to encapsulate ingredients that are sensitive to oxygen, such as probiotics.3 Due to their composition and origin, they are also commonly utilized in supplements that are certified as organic, vegan, and allergen-free. They also appeal to the growing demand for eco-friendly products because they are biodegradable and come from a sustainable source.
Manufacturers need capsules that protect ingredients, align with consumer needs, and work seamlessly with existing capsule filling equipment. Over other types of empty capsules, manufacturers often choose pullulan capsules for their functionality and consumer appeal.
Here’s why manufacturers prefer pullulan capsules:
One of the most evident advantages of pullulan capsules is their exceptional oxygen barrier, which is significantly stronger than those of both HPMC capsules and gelatin capsules. This is important because many nutraceutical ingredients degrade when exposed to oxygen. Probiotics, botanicals, enzymes (such as Bromelain), and omega-3s (like Flaxseed Oil) can lose bioavailability if they are not properly protected. This is why the proper encapsulation is so vitally important. Pullulan capsules help prolong shelf life by blocking oxygen exposure, ensuring that active ingredients remain stable for longer.
The demand for vegan and plant-based supplements is still experiencing growth. The vegan supplement market’s valuation was estimated to be around USD 9.1 billion in 2024 and is projected to grow to USD 17.7 billion by 2034 at a CAGR of 6.9%.4 Consumers are desiring clean-label and non-GMO ethical alternatives to traditional animal-derived products like gelatin; for instance, more than 2 in 3 consumers globally believe they are somewhat influenced by a clean label.5
Efficiency in capsule filling, storage, and packaging are important aspects to manufacturers. With their strong elasticity and durability, pullulan capsules are compatible with practically any type of high-speed capsule filling machine. Pullulan capsules possess strong film-forming properties that create a protective barrier.6 In the correct environmental conditions, pullulan capsules are less likely to become brittle and break during encapsulation in comparison to gelatin capsules.
The manufacturing of pullulan capsules results in a low environmental impact. Pullulan is produced through a fermentation process of a naturally occurring fungus, which makes it a sustainable option. Unlike gelatin, which is derived from animal collagen through intensive processing, pullulan is cultivated in controlled environments with minimal resource consumption. As a plant-based, organic material, pullulan capsules are also biodegradable.7
The following is a table that displays the features discussed above as well as a few additional ones:
Pullulan capsules are a versatile option for supplement manufacturers, especially for formulas that require high oxygen protection, plant-based sourcing, and compatibility with sensitive ingredients. They work well with a wide range of nutraceuticals, herbal extracts, and specialty supplements.
Probiotic supplements include living bacteria that require protection from air, moisture, and heat to remain efficacious in the human body. Because oxygen exposure can rapidly impact stability, pullulan’s oxygen barrier extends shelf life and maintains good bacterial viability throughout storage and transportation. Some studies have even indicated that pullulan also has prebiotic benefits.8
Why pullulan capsules are ideal for probiotics:
Many herbal and botanical extracts are extremely vulnerable to oxidation, moisture exposure, and deterioration over time. Pullulan capsules protect active ingredients, ensuring the bioavailability of herbal formulations.
Why pullulan capsules work for herbal supplements:
Sports supplements with amino acids have clean-label, high-quality delivery solutions that can satisfy the demands of health-conscious athletes. Pullulan capsules are a great option for fitness supplement manufacturers wanting to avoid synthetic materials and gelatin-based capsules.
Why pullulan is great for sports supplements:
For specialty formulations that require high stability, regulatory compliance, or plant-based sourcing, pullulan capsules are a good choice for manufacturers.
Examples of pullulan capsules’ uses in specialty supplements:
Encapsulation machines require capsule compatibility to ensure successful production, minimal waste, and high product quality. Pullulan capsules are intended to work with most common encapsulation equipment, however there are some best practices to follow for the best operational performance.
Pullulan capsules are compatible with most capsule filling machines; however, small adjustments to the machine may be needed to ensure optimal performance, especially for manufacturers transitioning from using a different type of capsule.
Key Production Factors for Pullulan Capsules:
Proper storage and handling is very important to maintaining the structural integrity of pullulan capsules. If they are not stored or handled correctly, there is a risk of capsule degradation happening.
Best Practices for Storing Pullulan Capsules:
What to Avoid When Storing Pullulan Capsules:
Pullulan capsules work well with a wide range of formulations, but manufacturers should be aware of certain filling properties that can assist with the smooth operation of the capsule filler.
Important Filling Considerations:
Manufacturers must guarantee that their capsule materials meet global regulatory standards in order to remain compliant and promote their products effectively. Pullulan capsules have a considerable benefit in this regard because they are obtained from natural, fermentation-based sources, making them appropriate for several dietary and religious restrictions.
Pullulan capsules meet important international supplement and pharmaceutical standards, making them a reliable option for global distribution. They are safe for human consumption in the United States since they comply with FDA17 and USP (United States Pharmacopeia)18 requirements. In the European Union, they comply with EFSA (European Food Safety Authority)19 standards, allowing them to be used in dietary supplements sold throughout the continent. Pullulan capsules also meet the criteria of the Japanese Pharmacopeia (JP), ensuring its global recognition.20
Pullulan capsules can be attractive to consumers since they can achieve various third-party certifications, making them more marketable for clean-label brands. Their plant-based origin qualifies them for vegan and vegetarian certifications, so they are a good fit for companies that cater to plant-based consumers.
Pullulan capsules are also Kosher and Halal approved, allowing supplement companies to offer products to religious dietary sectors. Many pullulan capsules are also non-GMO certified, which is becoming increasingly important to consumers looking for ingredient transparency in their supplements.
As consumers grow more careful of ingredients in their supplements, they often seek out products that meet organic, allergen-free, and sustainable standards. Pullulan capsules are free of animal derivatives, allergens, and synthetic materials, causing them to be a safer and more appealing choice for people with dietary restrictions.
Some pullulan capsules may qualify for organic certification because they are created using a fermentation technique rather than chemical alteration, depending on the supplier. This allows businesses to enter the growing organic supplement sector, which is driven by customer demand for clean, minimally processed products.
Before deciding on purchasing pullulan capsules, manufacturers need to consider factors such as capsule size, customization options, and supplier reliability. These factors play an important role in ensuring smooth operation, regulatory compliance, and strong market positioning for your encapsulated product.
Dosing accuracy, ingredient compatibility, and consumer experience directly influence the capsule size of your product. Pullulan capsules come in industry-standard sizes, with the most widely used being 00, 0, 1, and 2.
Larger capsules, such as size 00, are commonly used for high-dosage formulations like amino acids, herbal extracts, or multi-ingredient blends, while smaller capsules, such as size 2, are ideal for precise microdoses or powerful extracts.
Factors to Consider When Choosing Capsule Size:
Custom capsules can be beneficial for brand identification, product distinction, and consumer loyalty. Pullulan capsules are available in transparent, opaque, and colored forms, allowing manufacturers to customize their capsules to meet specific branding and product requirements.
Transparent capsules are suitable for displaying high-quality materials like herbal powders or beadlet formulations, but opaque or colored capsules can shield sensitive substances from light while still adding visual appeal.21
Manufacturers can also custom print logos on pullulan capsules to make them more identifiable and memorable.
To ensure high quality, regulatory compliance, and successful manufacturing, choose a dependable pullulan capsule supplier. Because pullulan capsules are used to create ingestible products for the nutraceutical and pharmaceutical industries, procuring from a supplier who is committed to following strict quality assurance standards is of the utmost importance.
Evaluate pullulan capsule distributors based on the following:
Pullulan capsules are a standout encapsulation solution for supplement manufacturers seeking a plant-based, high-performance, and clean-label alternative to standard gelatin capsules or HPMC capsules. Their excellent oxygen barrier, compatibility with sensitive ingredients, and ability to meet global regulatory standards make them a valid choice for a variety of applications, including probiotics, herbal extracts, sports nutrition, and functional supplements.
With pullulan capsules, manufacturers can guarantee product stability, appeal to health-conscious consumers, and increase their market reach into vegan/vegetarian, Kosher, Halal, and non-GMO products. If you’re looking to protect ingredients, establish branding with custom capsules, or address the rising demand for sustainable and plant-based supplements, pullulan capsules have the flexibility and dependability your production requires.
If you’re thinking of using pullulan capsules for your next product, why not test them first? Vivion offers free capsule samples to help you test them out with your formulation. Whether you need pullulan, gelatin, or HPMC capsules, our team can help you find the best option for your product line. Contact Vivion today to speak with the capsule experts.