Problem: Many supplement brands—and consumers—feel confused when choosing capsule sizes for their products.
Agitation: Choosing the wrong size can affect dosing accuracy, product appeal, and customer satisfaction. This leads to reformulations or returns.
Solution: This complete guide breaks down capsule sizes, volume capacity, pros and cons, and how to choose the right one for your supplement needs.
Capsule sizes range from 000 (largest) to 5 (smallest). A 00 capsule holds about 400–500 mg powder, while a 2 capsule holds 200–250 mg. Size affects dosage, swallowing comfort, cost, and branding. Knowing your active ingredient weight and consumer preference helps you pick the ideal capsule size for your formulation and market.
Before you rush to choose a capsule size, it’s vital to understand each option. The wrong pick can hurt your product’s effectiveness and brand image. Let’s explore the details now.
1. What are standard capsule sizes and volumes?
Capsule sizes are standardized from 000 to 5. Each size varies in milligram capacity depending on powder density.
Size 000 holds ~1000 mg, size 0 ~400–500 mg, size 1 ~300 mg, size 2 ~200–250 mg, size 3 ~150 mg, size 4 ~120 mg, size 5 ~100 mg.
Capsule sizes correspond to internal volume (mL). Powder densities (e.g., protein vs vitamin) affect fill weight. Consider compressibility and flow. Include labeling compliance in fill volume estimates.
* Standard sizes make formulation predictable.
* Always request sample fill tests during development.
2. How do capsule sizes affect dosage and formulation?
Capsule size directly affects the number of pills your customer must take.
A larger capsule lets you pack more active ingredients per dose, reducing pill count but possibly impacting swallowability.
A daily dose of 1g could mean two 00 capsules or four size 2 capsules. Filling multiple units increases production and packaging complexity. Some actives require excipients to improve flow—affecting size choice. The balance between pill count and swallow comfort is key.
* Reducing pill count increases customer adherence.
* Small capsules may require blend optimization.
3. Which capsule size is easiest to swallow?
Swallowing comfort affects user experience and repeat purchase.
Capsule sizes 1–2 are typically easiest for adults; children and seniors often prefer size 3 or soluble tablets.
User demographics matter. Surveys show many find 00 capsules too large. Use consumer feedback or ergonomic tests. Gelatin vs. veggie capsules also differ in coating texture. Coatings can reduce friction.
* Size 1–2 offers best balance of dose vs. swallow ease.
* Coating improves swallowability.
4. How does capsule size impact cost and packaging?
Size affects raw material volume, packaging space, and shipping weight.
Larger capsules cost more per unit and require larger bottles, which increases shipping and shelf space costs.
A bottle of 60 00-capsule costs more than 120 size 2 capsules per bottle. Shipping costs scale with weight. CAPEX for filling machines also varies. Packaging designs must match capsule size accordingly.
* Capsule size directly affects production and logistics cost.
* Matching bottle design avoids space waste.
5. How to choose the right capsule size for your product?
A good choice considers dose, consumer, cost, and brand image.
Start with your active dose and powder density. Then test with target consumer group and budget.
Calculate desired dose and powder density. Then trial-fill capsules in sizes 0–2. Gather feedback on swallowing. Model per-unit cost and bottle design. Optimize balance between capsule count, cost, and user experience.
* Pilot fills help validate size choice.
* Capsule size affects both cost and sales potential.
6. What factors influence manufacturing decisions?
Manufacturers consider fill efficacy, line speed, and QC.
Smaller capsules may slow down filling lines. Large capsules need more cleaning time and quality checks.
Fill machines handle sizes 0–2 best. Larger/very small sizes need specialty tooling and changeovers—adding time and cost. QC inspections verify fill weight and integrity. Regulators expect consistent dosage per capsule.
* Filling efficiency varies by size.
* Capsules outside 0–2 may need special equipment.
Choosing the right capsule size requires balancing dosage, swallow ease, cost, and production feasibility. Most brands find sizes 0–2 offer the best mix. Test extensively, involve consumers, and align with manufacturing capabilities. The right size boosts product success and user loyalty.
Selecting capsule sizes involves precise calculation and user testing. Aim for sweet spots like size 0–2. Always pilot test and align with production partners.
Shandong Health Biotech Supports Your Capsule Supplement Vision
Still unsure which capsule size fits your formula best? Don’t worry—Shandong Health Biotech is here to support your supplement business from start to finish. Whether you’re launching your first product or scaling an existing line, our team is ready to help.
We are a seasoned capsule supplement manufacturer based in China, offering private label and custom capsule manufacturing for global health brands. With over 16 years of manufacturing expertise, we’re equipped to serve startups and large-scale enterprises alike.
Our capsule services cover every need, including:
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Capsule sizes from #5 to 000 to fit any dosage range
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Capsule types including gelatin, HPMC, vegan, halal, and organic
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Color matching, brand-themed capsule design, and shell printing
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Labeling, packaging, and full OEM/ODM support
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A wide choice of stock capsule formulas like ashwagandha, spirulina, and more
Our factory produces millions of capsules daily, powered by:
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GMP, ISO, HACCP-certified cleanroom production
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Automated lines that ensure consistency and efficiency
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In-house formulation and quality control teams
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Free consultation, quotations, and sample support
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Ability to manage both simple and complex custom formulas
At Shandong Health Biotech, we believe the right capsule size is just the beginning. We’re here to make your product vision real—with speed, quality, and precision.
📩 Contact us today to get started with your capsule supplement project.
