Capsules pair a shell (hard gelatin or HPMC) with a fill (powders with excipients or oil-based liquids). Shell material affects stability and dietary suitability; common fillers include microcrystalline cellulose for powders and vegetable oils for softgels. Filling equipment ranges from manual devices for R&D to automatic machines for commercial production. Manufacturers such as Lonza (formerly Capsugel), IMA, Romaco, and Syntegon supply capsule and softgel equipment. Capsules and processes must meet pharmacopeial standards.

What a capsule is and how it works

A capsule combines a shell and its fill. The shell contains and protects the active ingredient(s); the fill contains the active plus inactive excipients (fillers, flow aids, binders). Capsules make oral dosing easier, mask unpleasant tastes, and help control release.

Capsule shell types

  • Hard capsules: two-piece shells traditionally made from gelatin. Plant-based alternatives use hydroxypropyl methylcellulose (HPMC), often called "vegetarian" or "cellulose" capsules.
  • Softgels: one-piece gelatin shells designed for liquid or semi-solid fills. Gelatin is derived from collagen found in animal connective tissues (bovine, porcine, or fish). Gelatin-free softgel alternatives exist for vegetarian or religious preferences.

Common fills and excipients

For hard capsules (powders/granules): microcrystalline cellulose, lactose, dicalcium phosphate, starch, and small amounts of lubricants (e.g., magnesium stearate) are typical. These excipients improve flow, uniformity, and compactness.

For softgels (liquids/oils): manufacturers commonly use vegetable oils such as soybean oil or medium-chain triglycerides (MCT) as primary carriers. Solubilizers, antioxidants, and viscosity modifiers help stabilize oil-based fills.

Why fillers and shell choice matter

The shell and the fill interact. Shell composition affects stability, dissolution, and consumer acceptability (e.g., vegetarian labeling). Liquid fills require a flexible, often gelatin-based shell; powders need shells that seal and resist moisture. Excipients inside the capsule ensure consistent dosing and processing performance.

Capsule-filling equipment

There are three practical classes of capsule filling equipment:
  • Manual machines: simple, low-output devices used for small batches, research, and development.
  • Semi-automatic machines: higher throughput, suitable for small-scale production and compounding pharmacies.
  • Automatic machines: fully automated, high-speed production for commercial-scale manufacturing.
Manufacturers and suppliers of capsule and softgel equipment include Lonza (formerly Capsugel), IMA, Romaco, and Syntegon, among others. Equipment choice depends on batch size, regulatory requirements, and the physical properties of the fill.

Regulation and quality

Pharmaceutical and dietary supplement capsules are regulated and must meet pharmacopeial standards (for example USP and Ph. Eur.) for content uniformity, dissolution, and stability. Manufacturers validate machines and processes to ensure consistent dose delivery.

Practical tips for consumers

If you avoid animal products, look for HPMC shells or explicitly labeled vegetarian/vegan capsules. Store capsules in a cool, dry place to protect shell integrity and active ingredients.

FAQs about Capsule Filler

Are all capsules made from animal gelatin?
No. Hard capsules can be made from HPMC (a plant-derived cellulose) and labeled vegetarian. Softgels are usually gelatin-based, though gelatin-free softgel alternatives are available for specific applications.
What’s the difference between a hard capsule and a softgel?
Hard capsules are two-piece shells filled with powders or granules. Softgels are one-piece, flexible shells designed for liquid or semi-solid fills and typically use gelatin.
What common fillers are used inside capsules?
Powder fills often use microcrystalline cellulose, lactose, dicalcium phosphate, and flow agents like magnesium stearate. Liquid fills typically use vegetable oils (e.g., soybean oil or MCT) plus stabilizers.
How do I choose between manual, semi-automatic, and automatic filling machines?
Choose based on batch size and regulatory needs: manual for small test batches and R&D; semi-automatic for moderate-scale production or compounding; automatic for high-volume, validated commercial manufacturing.
Do capsules require special storage?
Yes. Store capsules in a cool, dry place away from high humidity and direct heat to preserve shell integrity and active ingredient stability.

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