Capsule Manufacturer India | HPMC & Gelatin

What Are Nutraceutical Capsules?

Capsules: The Preferred Dosage Form for Nutraceutical Supplements

Capsules are two-piece solid dosage forms consisting of a cylindrical shell that encases a precise quantity of powdered, granulated, or pelletised active ingredients. In nutraceutical manufacturing, capsules are produced using either gelatin (derived from bovine or porcine collagen) or HPMC — hydroxypropyl methylcellulose — a plant-derived polymer suitable for vegetarian, vegan, and halal-certified products. The two halves of a hard-shell capsule are filled on high-speed automatic encapsulation machines that dose each unit to milligram-level accuracy, ensuring consistent potency across every batch.

Hard capsules are available in standard sizes numbered 00 (the largest, holding approximately 735 mg of powder) through size 4 (the smallest, holding roughly 120 mg). Manufacturers can apply functional coatings — including enteric, moisture-barrier, and sustained-release films — directly onto the capsule shell, enabling targeted delivery without altering the fill formulation. This versatility makes capsules the most adaptable oral solid dosage form available in the Indian nutraceutical industry today.

Capsules account for over 40% of all nutraceutical dosage forms sold in India, preferred for their ease of swallowing and precise dosing.

Product Overview

HPMC Vegetarian vs. Gelatin Capsules

Choosing the right capsule shell is one of the most important formulation decisions a brand can make. At Bionial Lifesciences, we manufacture both HPMC vegetarian capsules and traditional gelatin capsules, giving you complete flexibility to meet your target market's dietary, religious, and regulatory requirements.

HPMC (Vegetarian) Capsules

Our HPMC capsules are manufactured from plant-derived cellulose, making them inherently vegetarian, vegan, halal, and kosher. With a moisture content of just 3-7% (compared to 13-16% in gelatin), HPMC shells are the ideal choice for moisture-sensitive actives such as probiotics, digestive enzymes, and hygroscopic herbal extracts. The lower moisture also contributes to improved long-term stability, particularly in tropical climates like India where humidity can compromise product integrity.

Gelatin Capsules

Gelatin capsules remain the global standard for nutraceutical encapsulation, offering excellent fill-weight flexibility, rapid disintegration (typically within 5-10 minutes in gastric fluid), and a cost advantage of approximately 15-20% over HPMC. They are well-suited for non-vegetarian product lines, omega-3 blends, and formulations where fast dissolution is a clinical priority.

Capsule Sizes & Variants

Available Capsule Configurations

Bionial supports the full range of hard-shell capsule sizes and multiple release technologies. Whether you need a standard immediate-release capsule for a daily multivitamin or an enteric-coated delayed-release shell for a probiotic blend, our manufacturing line is configured to deliver.

Size 00 — Up to 735 mg fill weight. Ideal for high-dose single-ingredient formulations such as calcium, magnesium, or bulky herbal powders.
Size 0 — Up to 500 mg fill weight. The most popular size for nutraceutical capsules globally; used for multivitamin blends, ashwagandha, and curcumin formulations.
Size 1 — Up to 400 mg fill weight. Suitable for medium-dose actives including CoQ10, Bacopa monnieri, and Citicoline.
Size 2 — Up to 300 mg fill weight. Used for concentrated extracts, single-nutrient capsules, and pediatric-friendly formulations.
Size 3 & 4 — Up to 200 mg and 120 mg respectively. Compact sizes used for concentrated botanical extracts, piperine enhancers, and melatonin micro-dose capsules.

Delayed-Release & Enteric Coating

For acid-labile ingredients that must bypass the stomach and dissolve in the intestine, Bionial applies pharmaceutical-grade enteric coatings using polymers such as HPMC phthalate (HPMCP) and methacrylic acid copolymer (Eudragit). This technology is critical for probiotics, digestive enzyme blends, and certain Ayurvedic extracts that are degraded by gastric acid. Our enteric capsules reliably resist dissolution at pH values below 5.5 and release their contents within 30 minutes at intestinal pH (6.8 and above).

Manufacturing Capabilities

End-to-End Capsule Manufacturing at Bionial

Our WHO-GMP certified facility in Mohali, Punjab is equipped for complete capsule manufacturing from raw material receipt through finished goods packaging. Every stage is documented with full batch traceability.

Powder Blending & Granulation

V-blenders and octagonal blenders ensure uniform distribution of active ingredients and excipients before encapsulation, with blend uniformity verified to USP standards.

Automatic Encapsulation

High-speed encapsulation machines fill capsule shells with milligram-precision dosing, supporting output of up to 100,000 capsules per hour per line.

Enteric & Film Coating

Perforated pan coating systems apply enteric, moisture-barrier, and colour coatings to capsule shells for targeted delivery and brand differentiation.

Polishing & Sorting

Capsule polishing machines remove residual powder from shell surfaces, followed by weight-sorting and visual inspection for cosmetic defects.

Blister & Bottle Packing

Alu-alu and PVC-aluminium blister lines, HDPE bottle filling, and strip packaging — all configured for GMP-compliant primary and secondary packaging.

Quality Control Laboratory

In-house HPLC, dissolution testing, disintegration testing, moisture analysis, and microbial limit testing ensure every batch meets specification before release.

Quality Assurance

Certifications & Quality Standards

Every capsule manufactured at Bionial is produced under strict regulatory compliance, backed by six certifications and rigorous in-process quality checks.

WHO-GMP

World Health Organization Good Manufacturing Practice certified facility

FSSAI

Food Safety and Standards Authority of India licensed manufacturer

AYUSH GMP

Ministry of AYUSH certified for Ayurvedic capsule manufacturing

ISO 22000

Food safety management system certification for entire supply chain

HACCP

Hazard Analysis and Critical Control Points implemented across all lines

GLP Compliant

Good Laboratory Practice standards in our quality control laboratory

Patented APIs

Patented Ingredients Available in Capsule Form

Bionial formulates with 50+ globally patented ingredients. These branded APIs are available in our capsule manufacturing line.

KSM-66 Ashwagandha

Ixoreal Biomed

Full-spectrum root extract, 5% withanolides. Clinically validated for stress, testosterone, and sleep support.

Cognizin Citicoline

Kyowa Hakko

Branded CDP-choline for cognitive focus, memory, and brain energy metabolism. 500 mg per capsule.

BacoMind Bacopa

Natural Remedies

Standardized Bacopa monnieri extract with 9 bioactives for memory enhancement and neuroprotection.

Magtein Magnesium L-Threonate

AIDP / Magceutics

The only magnesium form clinically shown to cross the blood-brain barrier for cognitive benefits.

Sensoril Ashwagandha

Natreon Inc.

Dual root-and-leaf extract with high withanolide glycoside content for enhanced bioavailability.

Shoden Ashwagandha

Arjuna Natural

35% withanolide glycosides — the highest concentration ashwagandha extract available globally.

UC-II Undenatured Collagen

Lonza

40 mg of undenatured type II collagen for joint comfort and mobility, proven in clinical studies.

Curcumin C3 Complex + BioPerine

Sabinsa Corporation

Patented curcuminoid complex with piperine enhancement delivering up to 20x improved absorption.

Frequently Asked Questions

Capsule Manufacturing FAQ

What types of capsules does Bionial manufacture?

Bionial manufactures both HPMC (hydroxypropyl methylcellulose) vegetarian capsules and standard gelatin capsules. We offer hard-shell capsules in sizes 00, 0, 1, 2, 3, and 4, as well as enteric-coated and delayed-release capsule variants for acid-sensitive ingredients. Our facility supports both clear and coloured shells with custom printing options for brand differentiation.

What is the difference between HPMC and gelatin capsules?

HPMC capsules are made from plant-derived hydroxypropyl methylcellulose, making them suitable for vegetarian, vegan, and halal-certified products. Gelatin capsules are derived from animal collagen and offer a lower cost per unit. HPMC capsules have significantly lower moisture content (3-7% vs. 13-16%), making them the better choice for moisture-sensitive ingredients like probiotics, digestive enzymes, and hygroscopic herbal extracts. Gelatin capsules dissolve faster in gastric fluid and are preferred for cost-sensitive product lines.

What is the minimum order quantity for capsule manufacturing?

Bionial offers a minimum order quantity starting from 1,000 units per SKU for capsule manufacturing. This low MOQ makes us ideal for D2C brands, supplement startups, and clinical trial batches. For larger orders, we offer volume-based pricing with batch sizes up to 500,000 capsules per production run. Our standard turnaround is 30 days from purchase order to dispatch.

Can you manufacture enteric-coated capsules?

Yes. Bionial manufactures enteric-coated capsules designed to resist dissolution in the acidic stomach environment (pH below 5.5) and release their contents in the alkaline intestinal tract (pH 6.8 and above). This is essential for acid-sensitive ingredients like probiotics, digestive enzymes, serrapeptase, and certain Ayurvedic extracts. We use pharmaceutical-grade polymers including HPMCP and Eudragit for reliable enteric protection.

What is the typical shelf life of capsules manufactured by Bionial?

Capsules manufactured at Bionial typically carry a shelf life of 24 to 36 months when stored under recommended conditions (below 25 degrees Celsius, below 60% relative humidity). The exact shelf life depends on the active ingredients, excipients, packaging format, and storage conditions. We conduct accelerated stability studies (40 degrees / 75% RH for 6 months) and real-time stability testing as part of our standard quality assurance process for every new formulation.

Capsule Manufacturing — HPMC & Gelatin Capsules, WHO-GMP Certified