Capsules remain one of the most popular supplement delivery systems due to their enhanced absorption, convenience, customizable dosing, and more.1 Not every nutraceutical ingredient is easy to encapsulate, though. Ingredients with poor flowability, high moisture sensitivity, or unusual particle sizes can cause challenges during manufacturing. These could create potential risks such as inconsistent capsule weights, production delays, or even compromised product quality.
This article offers a summary of nutraceutical ingredients that are well-known for their compatibility with empty capsules, consistent performance, and widespread use in the supplement industry to assist manufacturers in choosing ingredients that complement capsules. We’ll also discuss ingredients that might experience trouble during encapsulation and how producers might deal with typical capsule production issues.
Choosing ingredients suitable for capsules involves more than just considering their nutritional benefits. Manufacturers need ingredients that fill consistently, maintain stability, and meet quality standards. Here are some important factors to keep in mind:
Flowability, which is how easily a powder moves during manufacturing, is critical for successful encapsulation.2 Ingredients with good flow properties help ensure consistent capsule weights and dosing accuracy. Poor-flowing powders can clump or even clog capsule-filling equipment, causing production delays and inconsistent doses. Ingredients often benefit from excipients like magnesium stearate or silicon dioxide to improve flow and reduce sticking.
To increase the rate of each capsule having the correct amount of active ingredients, powder formulations need uniformly sized particles so powders can flow evenly into capsules.3 Irregular particle sizes can result in uneven filling, which ultimately affects dosage accuracy and amount. Finely milled or granulated ingredients with consistent particle distributions can mean smoother encapsulation.
Particularly when manufacturing with hygroscopic ingredients, low moisture content in the encapsulation formulation is essential.4 Powders that absorb moisture easily can clump, degrade, or negatively interact with capsules themselves, affecting both the integrity and shelf life of the product. Dry ingredients ensure better stability and consistent filling performance.
Ingredients used with vegetarian substitutes like HPMC capsules and pullulan capsules, or even with the animal-derived gelatin capsules, must be chemically and physically compatible. While HPMC capsules provide more stability for sensitive substances, gelatin capsules have higher moisture levels and might not be suitable for ingredients that are sensitive to moisture.5 Reactions like softening, brittleness, and cross-linking can be avoided by selecting the appropriate capsule material that works with the supplement formulation.
Like with any nutraceutical product, compliance with quality standards is of the utmost importance. Reputable bulk ingredient suppliers usually prioritize quality assurance, providing clear documentation, such as Certificates of Analysis (COAs), specifications, and statements verifying they meet regulatory standards. Proper documentation helps manufacturers stay compliant, ensures consistent quality, and streamlines regulatory audits.
Selecting ingredients specifically known for excellent capsule compatibility makes production efficient and reliable. Here are top choices:
Certain nutraceutical ingredients have significant health benefits but can be challenging to work with during encapsulation. With solutions such as adjustments to the production environment and the addition of excipients to the formulation, these ingredients can still be encapsulated effectively:
Hygroscopic ingredients that absorb moisture from the environment can lead to clumping, sticking, or degradation of the active ingredient. Without the correct measures, these issues can slow down production or affect overall product quality.
These ingredients are commonly used in larger quantities, which can exceed the fill limits of standard capsules. Formulators must consider capsule size and dosage per serving when working with these ingredients and capsules.
Some powders develop static or have physical traits that make them difficult to control during encapsulation. These issues can lead to powder sticking to machinery, inconsistent fills, or cross-contamination between runs.
Excipients are inactive ingredients that have a significant effect on how effectively a formulation works during capsule filling.22 When used correctly, they can help solve common problems like poor flow, uneven fill weights, sticking, and clumping. These issues can impact production, and using the right excipients can help towards avoiding downtime.
Incorporating these excipients helps manufacturers achieve consistent capsule weights, minimize downtime, and reduce product variability, leading to higher quality and efficiency.
If you are working with nutraceutical ingredients, empty capsules are a popular and effective delivery system. However, not every ingredient functions the same way, and even small differences can have an influence on your fill process, product quality, and productivity.
Here are a few things to keep in mind:
Encapsulating nutraceutical ingredients isn’t one-size-fits-all. Flowability, dosage size, and compatibility with capsule shells all affect how well an ingredient performs in production. But with the right planning and the right materials, capsules remain one of the most efficient and effective delivery forms for supplements.
Vivion supplies a wide range of nutraceutical ingredients and excipients, including empty gelatin, HPMC, and pullulan capsules, to support your full capsule formulation process. With consistent quality, dependable stock, and complete documentation, we help you keep production running smoothly. Contact us today to get a quote or request samples.