In the pharmaceutical and nutraceutical manufacturing industry, understanding capsule sizes and their compatibility with capsule filling machines is fundamental to production efficiency, dosage accuracy, and regulatory compliance.
The selection of appropriate capsule sizes directly impacts multiple aspects of drug manufacturing:
·Therapeutic efficacy through precise dosage delivery
·Production efficiency and capsule machine compatibility
·Patient compliance and market acceptance
·Regulatory adherence and cost control
This guide will offer a detailed capsule size chart to illustrate sizes of capsules, and examine the relationship between capsule dimensions (from 000 capsule size to 5 capsule size) and capsule filler filling machines, along with an in-depth analysis of modern capsule filling technologies, providing pharmaceutical manufacturers with essential knowledge to optimize their production processes.
Capsule sizes follow an internationally recognized numbering system where capsule size 000 represents the largest volume and size 5 indicates the smallest. This capsule size variation directly correlates with drug loading capacity.
The consequences of improper size selection can be clinically significant, including:
·Underfilled capsules may result in sub-therapeutic dosing.
·Overfilled capsules will lead to inconsistent drug release profiles.
·Improperly sized capsules may affect dissolution rates and bioavailability.
We hereby provide the capsule size chart:
Clearly shown by the capsule size chart, ranging from 000 (the largest capsule size) to 5 (the smallest capsule size), various sizes have different capacities and capsule dimensions. Size 000 capsules (1.37mL volume) can accommodate approximately 1,600mg of standard density powder, making them ideal for high-dose formulations like certain antibiotics or fiber supplements.
Measured in milliliters (ml), it refers to a capsule’s internal space or holding capacity, which determines the maximum amount of powder, granules, liquid or semi-solid formulation that a capsule can contain.
It indicates the weight of a capsule shell, inclusive of both the body and cap, without any active pharmaceutical ingredient (API), excipients or other fill materials. It is the baseline weight of the capsule before filling, used for quality control and formulation calculations. Every capsule maker needs to ensure consistent empty capsule weight to avoid inconsistencies of capsule filling.
It refers to the maximum amount of drug powder, granule or liquid that can be filled into a single capsule shell. Typically this loading capacity is measured in mg. The capacity depends on the size of the capsule (larger capsules hold more) and the formulation density (light powders take up more volume but may weigh less).
This means the overall length of a capsule (a cylindrical object with hemispherical ends) when it is in its fully closed or compact state. The length is measured from a capsule’s one end to another end when the capsule is not extended or opened. This measurement is important in for the precise packaging of capsules.
This kind of length refers to the measurement of the capsule body and cap separately before they are joined together. The longer part of a capsule calls the body— main part of a capsule that holds API. Comparatively, the capsule cap is the shorter, domed end that suits the body to lock a capsule.
Capsule filling is a critical process in pharmaceutical manufacturing, requiring precision, efficiency and compliance with industry standards. Two main kinds of machines dominate the market: semi-auto and fully auto capsule filler filling machines. A key consideration for manufacturers is whether these machines can handle the full range of capsule sizes (from 000 to 5) and which type offers good investment return.
a semi-auto capsule filling machine
Most semi-automatic capsule filling machines support size 000 capsules to size 5 capsules, but with manual adjustment for different sizes. However, operators must change components (e.g., dosing discs, tamping pins, and holding rings) when switching capsule sizes, which can slow the production. Therefore, semi auto capsule filling machines best suit small-batch production, R&D, or clinical trials where flexibility is more critical than speed.
Automatic capsule fillers can handle size 000 to size 5 capsules and quickly fill a huge number of capsules, often with quick-change systems that minimize downtime. Some models feature auto-adjustment mechanisms, eliminating manual intervention when switching capsule sizes. Thus, auto capsule filling machines are ideal for mass production where uninterrupted operation and high output are essential.
a fully auto capsule filler
Both machine types can fill all standard capsule sizes, but fully automatic models offer greater efficiency in batch production and capsule size switching.
While semi-auto capsule filling machines are cost-effective for small operations, fully automatic capsule filler filling machines provide significant advantages:
· Higher Production Speed
Semi-auto capsule filler machines typically fill 10,000 to 15,000 capsules/hour, depending on operator skill. For some high-end models such as Rich Packing’s CGNT-209 semi auto capsule filler, filling 38,000 capsules/hour can be realized.
In comparison, fully automatic capsule fillers can achieve 50,000 to 200,000 capsules/hour, making the production capacity 50 to 200 times larger. In terms of high-end models, auto capsule filling machines can fill 330,000 capsules/hour. For example, a NJP-5500D capsule filling can reach this max output.
·Improved Accuracy & Consistency
Manual dosing in semi-auto pill capsule machines may lead to weight variations. By contrast, fully automatic capsule powder filling machines use precision dosing systems for ±1% to 3% weight uniformity, ensuring compliance with USP and Ph. Eur. standards.
·Reduced Labor Dependency
Semi-auto capsule making machines require constant operator involvement, such as loading capsules, checking the filling, and adjusting parts. Compared with this, fully automatic pill capsule fillers run with minimal personnel supervision, reducing labor costs and human errors.
With the full enclosure design, fully auto pill capsule making machines minimize human contact, critical for cGMP compliance. Compared to this item, semi-auto processes involve more manual handling, increasing contamination risks.
Some fully auto pharmaceutical capsule filling machines feature tool-less changeover, reducing downtime. In contrast, semi-auto capsule filling machine fillers require more manual component replacements, slowing the production.
the main mechanism of a fully auto capsule filling machine
The decision depends on your production scale, budget, and future growth plans:
Choose a semi automatic capsule filling machine, if you:
·Produce only small batches (e.g., R&D, compounding pharmacies).
·Have limited budget, and labor costs are low.
·Need flexibility for frequent capsule size changes.
Choose a fully automatic capsule filler filling machine, if you:
·Require high-volume production in commercial manufacturing.
·Meet regulatory compliance that demands precision and minimal human intervention.
·Aim to scale up your production in the future.
For pharmaceutical manufacturers targeting future growth and regulatory excellence, investing in a capsule filling machine automatic is a smarter, future-proof choice.
Besides high production output, what are other important features that an advanced auto capsule filling machine displays?
A high-class automatic capsule filler is not just about speed, but is also about precision, reliability and compliance. Cutting-edge machines ensure consistent quality, minimal waste, and maximum uptime, making it indispensable for modern pharmaceutical manufacturing.
Take the NJP-5500D fully automatic capsule filling machine from Rich Packing for an example. Its maximum output achieves 330,000 capsules per hour, with its capsule separation success rate and finished product qualification rate respectively reaching 99.99% and 99.98%. The content below shows some advanced features of the NJP-5500D. Based on this information, you can know the essential quality of an ideal auto model and make thorough considerations before selecting your equipment.
In conventional capsule fillings, many APIs (Active Pharmaceutical Ingredients) and excipients exhibit poor flowability, causing inconsistent filling and weight variations.
In advanced models, with the help of pneumatic feeding system, smooth material flow is guaranteed even the material is of low flowability, reducing material clogging. In a result, the speed of material feeding can go up by 20% to 40% and the overall production capacity can increase by 25% to 40%.
Vibration-assisted dosing in some other models further enhances uniformity, especially for cohesive powders, resulting in more accurate fill weights (±1–3% deviation), minimizing waste and ensuring compliance with regulatory standards.
Traditional oiling can lead to contamination risks and messy operations.
Built-in cam-driven greasing system provides continuous, automatic lubrication to critical operational parts. No oil dripping ensures clean operation, meeting cGMP and FDA requirements. What’s more, machine lifespan can be extended due to reduced friction, and the risk of lubricant contaminating capsules will be dramatically reduced.
Dosing accuracy is critical for regulatory compliance and patient safety. In this case, high-precision indexing system using ZEISS optical technology ensures exact positioning of dosing stations. Besides, one-time machining of indexing shafts eliminates cumulative errors, making fill weight deviation lower than 3%.
In conventional equipment, powder leakage contaminates machines and production areas, increasing cleaning time and cross-contamination risks.
In high-class models, SIL-grade silicone sealing rings around the turntable completely block powder ingress. Hermetic sealing prevents dust escape, maintaining a cleanroom-compatible environment.
Modular components of a high-end pill capsule machine allow fast disassembly (<15 minutes) for equipment cleaning or capsule size changes. In addition, jog operation mode simplifies alignment and troubleshooting.
The modularity enables tool-free mold replacement, greatly reducing downtime between production runs.
Switching between pill capsule sizes should be effortless. In a bid to achieve it, pull-out slot design enables quick swapping of filling rods without tools.
Residual powder in molds will cause misaligned or defective capsules. After equipment upgrading, automated air-jet cleaning equips molds with self-clieaning function in order to remove powder between cycles. Moreover, stainless steel molds resist sticking and corrosion.
Even advanced machines may produce minor defects, like underfilled, misaligned, or damaged capsules. When it comes to the NJP-5500D capsule filler, vision-based or weight-check waste rejection systems auto detect and reject faulty capsules, effectively ensuring the uniform quality of capsules.
Both semi-automatic and fully automatic capsule fillers can handle size 000 capsules to size 5 capsules, but fully automatic capsule machines dominate in speed, accuracy and efficiency.
In contemporary pharmaceutical manufacturing, fully automatic capsule filling machines play a crucial role in ensuring efficiency, precision, and compliance with stringent regulatory standards. While high production capacity is a fundamental requirement, truly advanced machines distinguish themselves through innovative engineering, superior material handling, and intelligent automation.
ส่งอีเมล : manager@richpacking.cn
Building D, No. 226, Beishan Qiaotou Street, Haizhu District, Guangzhou City, Guangdong Province, China
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