Those who make their own supplements often already know how much of a game-changer a capsule filling machine is for production.

However, not everyone knows how to optimize their use so that they save even more precious time, effort and resources.

Here’s a quick run down of some of the most useful tips to consider for the next time you whip out your own capsule filler.

1. Prepping Ingredients for Optimal Results

Efficient capsule-filling starts with your ingredients: Just a little preparation here can go a long way in overall performance.

• Predicting your required powder weight(s): Although not necessary, knowing exactly how much powder you’ll use will make the whole capsule-filling process more efficient.

  For example, if you weigh out the powder before filling, you won’t have to use any guess work when it comes time to pour it into the machine. Otherwise, you’d have to keep adding more and more powder as you go. You’ll also more than likely be left with excess powder once they’re full.. which you’ll have to pour back into the container.

• Even mixing: If using multiple ingredients to fill your capsules, you’ll want to mix your supplements in a way that ensures even distribution of your active ingredients. This is vital if you want each capsule to hold the same amount, enhancing your final product’s efficacy.

  See our article on How to Make Your Own Supplements for the 3 rules of even powder-mixing.

• Grinding up larger-particle powders: Adding to mixing properly, a consistent size of particles throughout your mix will allow for smoother filling in your capsule machine. Running thicker-particle powders through a coffee grinder is an easy way to ensure it’ll flow as best possible. For a lot of powder, a high-powered blender (such as a Vitamix) can often combine both the mixing and grinding jobs nicely.

• Moisture control: Keep your ingredients dry and free from excess moisture, which can cause clumping and interfere with the capsule filling process. Always store your powders using an airtight container in a cool, dry environment.

Note: To properly prepare your ingredients, use our capsule formulation tool and follow the steps provided. It will inform you if you need to take any special action when mixing, such as geometric dilution, and how to do that quickly and easily. It will also predict how much powder you’ll need to mix so that your capsules have exactly the dosage you want, instead of just the amount each capsule can hold!

2. Choosing the Right Capsule Size, Material and hole count

The ideal capsule size and material will significantly impact your capsule filling machine's efficiency. Here's how you can choose the perfect combination for your custom supplements:

• Capsule size: Determine the capsule size appropriate for your desired supplement dosage. Generally, capsules come in sizes ranging from 000 (largest) to 5 (smallest). Choose a size compatible with your capsule filling machine and be sure to check its specifications.

• Capsule ingredient type: Select a capsule type that suits the preferences and needs of your target audience. Common options include:

  Gelatin: A widely used capsule material derived from animal collagen. It's versatile, easy to handle, and affordable.

  Vegetable-based: Plant-based alternatives to gelatin, such as HPMC (hydroxypropyl methylcellulose) or pullulan, are suitable for vegetarians and vegans, respectively.

• Capsule packaging style: You’ll want to choose the correct packaging style depending on what capsule filling machine you’re using.

• Separated Capsules: If using a manual capsule press, like our Core and Pro Series models, you’ll want separated capsules, as they come with the tops and bottoms in separate bags. This saves you the time of having to separate them one-by-one before use! 

• Joined Capsules: If you’re using a semi-automatic capsule-filler like our Pro-Op Series that separate the capsules for you, make sure to choose joined capsules. If the bag doesn’t say whether they’re joined or separated, they’re joined.

Note: Our detailed guide to choosing the correct capsule size will take out all the guess work involved, so you can ensure you know which size you need beforehand!

3. Setting Up Your Capsule Filling Machine for Efficiency

Configuring your capsule filling machine the right way will significantly speed up the capsule-making process. Here’s how to do that:

• Consult the manufacturer's guidelines: You’re probably thinking, “Really? They’re recommending I read the instruction manual?”
  
  You’d be surprised at how often we get calls with problems that could have been solved with one look at the instructions that came with the machine… or by watching the video instructions on our How to Use page. Always review and follow your capsule filling machine's manual or instructional materials for optimal setup and usage, as specific procedures may vary between models.

• Capsule orientation: If the machine takes separated capsules, make sure they are correctly sectioned for use within the machine – the longer portion of the capsule, also called the “body,” should be placed aside for use with the base, or “body plate.” The shorter portion, “top,” belongs with the “capping plate.” Mixing these up or using the wrong sides is a surefire way to delay you and possibly waste some product!

• Test runs: This is much more important for automatic machines, but nonetheless putting a few capsules in a manual press just to make sure you know how to do it before using is a great way to not waste capsules and powder by messing when actually making your product. A short test run with empty capsules can ensure the machine is functioning correctly before introducing supplement ingredients, as well as familiarize yourself with the process.

4. Streamlining the Capsule Filling Process

Once you've prepped your ingredients, chosen the right capsules, and setup your machine, it's essential to learn the most efficient techniques to minimize the time and effort required during the process. You may or may not be surprised to hear one more time that…:

• Use the instruction manual: Yup, again. When learning the machine, keep that manual out and refer to it at every step to make sure your actions line up with the instructions. It’s best practice to also follow along with that machine’s video instructions for any of the steps that may be hard to understand from pictures and text alone. If the manufacturer of your machine doesn’t provide videos for this purpose, consider a capsule filling company that does!

• Optimal filling capacity: As mentioned earlier, calculating the maximum capacity of your capsules for the specific ingredient you’re filling with makes it so that you won’t have to do any cleanup involving repackaging unused powder! Overfilling the machine as a result of not knowing how much powder to add may lead to spillage, waste and a mess.

• Use a powder scraper and tamper accurately: When filling the capsules with your supplement blend, use a scraper or spatula to evenly distribute the powder among the capsules. This can help prevent spillage and ensure consistent dosing. Then use a tamper to pack as much of the powder in as possible, repeating the scraping and tamping until no more powder can fit inside the capsule body. Make sure to do this along the outer edge of the machine where those capsule holes aren’t as quick to access as the center of the machine’s holes.

• Make your capsules in similar batches: Divide your supplement creation process into stages or "batches" for maximum efficiency. For instance, making all turmeric/black pepper capsules in one sitting will be faster than making multiple different supplement powders will. That’s because you won’t have to worry about extra steps like cleaning the machine between batches to prepare for the other powders, or calculating the amount of powder that will fit for each powder used.

• Dedicated machines: Like batching, having multiple machines with each one dedicated to only one supplement type will greatly increase workflow efficiency.

  For example, let’s say one of the substances you encapsulate regularly can stick to parts much more than others, making it slightly more difficult. Having one pill filler dedicated to the difficult substance and another dedicated to an easier supplement powder makes it so that you don’t have to worry about cleaning between production to remove the debris (because it’s the same product being filled).

  This also keeps from having to switch back and forth between dosage shifts, product lines, etc. that require adjustments such as switching the capsule size plates of the Pro-Op 300 Capsule Filling Machine. One machine can be dedicated to a specific capsule size, supplement type, viscosity, or any other attribute that makes sense for your production.

• Increased output to cost evaluation: For those that rely on making capsules in their businesses, it’s essential to calculate the cost to benefit ratio for choosing a higher output machine versus a lower output machine and employees to operate it. For example, our Pro Series 400 Hole can do 400 capsules every 5-10 minutes, but it requires pre-separated capsules, which may or may not cost more than joined. Whereas the Pro-Op 300 separates them for you and makes them faster, but ithas significantly more up front costs.

  It’s important to consider what it will cost overtime to operate, versus what the higher output machines will cost. Then choose the option that works best for your business in the long term, and has the highest ability to grow with you as your needs do.

• Clean as you go: Although obvious, this is essential to making the entire process easier once complete.. Keeping your work environment clean and tidy throughout the capsule filling process will also avoid cross-contamination, ensuring your custom supplements are high-quality and safe.

Final Thoughts

With these important strategies and tips, you can significantly improve the efficiency of your capsule filling process, allowing you to maker high-quality custom supplements with little effort and wasted time. From prep to setup and execution, these techniques will give you the best chance at reaching your capsule-making goals.

Ready to kick your supplement creation process up a notch with a better capsule filling machine? Check out the largest selection of manual capsule fillers on the market  today! If you have any questions, reach out directly or take a look through our extensive range of resources and support to take your personalized nutrition journey to the next level.

We’re always available to help those looking to improve their life or their business!