Custom Capsule Manufacturing

Custom Private Label Capsule Manufacturing

SMP stands for Supplement Manufacturing Partners. Our team is dedicated to being your partner in most efficiently manufacturing your growing vitamin business to scale.

We have capabilities to manufacture any nutraceutical capsule formula. From sourcing each ingredient in your formula, to post-encapsulation inspection — we do it all at the best prices and the fastest lead times. We have the experience to help you formulate a new product for your target audience, or discuss with you how to properly scale your manufacturing. As your partner, it is our job to deliver long-term capsule manufacturing success.

Capsules are one of the most versatile and most common forms of encapsulation for nutraceutical formulas. We can assist you with all of your stock or custom capsule manufacturing needs.

The Capsule Manufacturing Process

Before encapsulation, your formula must be blended to ensure an even distribution of ingredients in each capsule.

Once all ingredients in your formula are blended, they are filled into capsule shells. Capsule shells are commonly made of gelatin, vegetable, or pullulan, depending on the formula.

Each capsule is polished of any excess powder for a clean and finished look, followed by being inspected for any defects.

After capsules are manufactured, post-inspection, we run identity, potency, micro, and heavy metal tests to ensure pharmaceutical-grade quality. See our FDA registration verification here.

Capsule Blend Preparation Process

Before a capsule can be filled with its contents, there is plenty of work that goes into preparing the formula for encapsulation. The contents within capsules can be prepared by undergoing one of the following processes:

• Wet Granulation Process
• Dry Granulation Process

Wet Granulation Blend Capsule Manufacturing Water Phase

During the wet granulation process, you begin with the blend for the supplement ready and mixed. The mixed blend will then have water added to it.

The water will wet the powder, which creates an immobile layer of water between particles. With more and more water being added to the powder, the layer of water continually grows wider and will ultimately pass through the pores of the particles.

Wet Granulation Blend Capsule Manufacturing Evaporation Phase

Now that the blend has had water added to it, the next step is to evaporate the water. This helps the blend to strengthen and bind together.

To get the water out of the blend, it will be evaporated, which results in a very strong level of adhesion for the particles and causes the particles to group together and become larger. The size of the particles will be affected by many factors such as the blend, density, and the type and amount of binders added.

Wet Granulation Blend Capsule Manufacturing Drying Phase

The drying phase is last in the wet granulation blend process. This allows for the blend to stay in place in the capsule and prevents it from spilling out.

The final step is drying. For small batches, a tray drying oven is used, but for more automation and larger batches, fluid bed dryers are used. These dryers utilize a stream of warm and dehumidified air running through the base of the drying chamber. To keep the powder from being pushed out of the chamber, a fine mesh is in place to keep the powder in place.

Dry Granulation Blend Capsule Manufacturing

The process of dry granulation is commonly used when the product’s blend doesn’t behave properly when met with moisture and heat.

The main difference in this process is the fact that liquids are never introduced to the blend. With the prepared blend of ingredients, the powder will be fed into a machine that will apply immense pressure and force to make the powder more compact and increase the bulk density. The amount of force needed varies depending on the blend, its ingredients, and the desired density.

Capsule Encapsulation Process

Manufacturing a nutraceutical capsule is not done until the prepared contents are filled into the capsule.

When producing these capsules, the materials must first be gathered. Once all materials are prepared, they are joined with hot demineralized water and mixed via vacuum in a machine. Over time, the blend will have more hot water added, along with dyes and opacifants if needed. When ready, the mixture will be molded around steel pins into the correct size and shape of the capsule. Both ends of the capsule are then dried together. The temperature and humidity levels are monitored to correctly allow for optimal drying of the capsules.

After the process of preparing and drying the capsule, the cap and body will be trimmed to a 0.15 mm tolerance. The capsules are put together and are ready to be filled and sent out.

Capsule Shell Options

Capsule shells are most commonly either made of gelatin or are vegetarian-friendly:

Gelatin capsules are created with resources from animals such as bones and cartilage. One of the most common resources for this type of capsule is bovine collagen.

Vegetarian capsules are commonly developed with hypromellose (HPMC for short) or the water-soluble polysaccharide pullulan, which is produced from the fermentation of starch.

Different Types Of Capsule Contents

Capsules are a versatile form of encapsulation, a suitable mode of transport for a wide range of contents — liquids, powders, pellet blends, and more. The contents may influence the type of shell, as some behave as expected only in a certain capsule type.

Liquid-Filled

Powder-Filled

Pellet Beadlets

Manufacturing Capsules With Special Attributes

Part of what makes capsules great is that they can be manufactured to behave differently. One of the most notable implementations of this is creating a capsule designed to help deliver its contents at the most optimal time.

Enteric capsules are another form of specialized capsule that can be made. These capsules are designed to withstand stomach acid so the contents of the capsule are released in the intestines.

SMP Nutra is equipped with the best machinery and team to manufacture any capsule supplement for your brand, with the highest quality.

Capsule Manufacturing FAQ