Our unique Trufil® capsule filling method allows us to manufacture many formulations without standard excipients and flow agents such as magnesium stearate. With more than 60 years of experience, we support start ups and established supplement brands throughout the manufacturing process.
Whether you want to select an established White Label capsule product or manufacture your own bespoke formulations, our experienced team can help you identify the right one.
Why Choose G&G As Your Capsule Manufacturer?
With more than 60 years of experience, G&G Vitamins is one of the UK’s longest established supplement manufacturers. Capsule filling is at the heart of our business, and our manufacturing methods have been developed over decades of working with ingredients that have very different properties.
Excipient Free Capsule Manufacturing
G&G developed the Trufil® capsule filling method to manufacture many capsule formulations without standard excipients and flow agents.
Excipients such as magnesium stearate are commonly added to improve the flow of powders through high-speed manufacturing equipment. Our semi-automatic approach gives our experienced encapsulators greater control over the filling process, allowing many formulations to be manufactured without these additional ingredients.
Every formula is assessed individually to confirm whether it is suitable for excipient free manufacturing.
Experienced UK Manufacturing Team
Our capsules are manufactured in our UK based ISO Class 8 cleanroom by a highly experienced encapsulation team. Some members of the team have several decades of individual capsule manufacturing experience.
This experience helps us understand how ingredients with different densities, particle sizes and flow characteristics are likely to behave during production. We operate a selection of capsule filling machines so that we can identify the most appropriate equipment for each formulation.
Rigorous Quality Control
Every production batch is subject to established quality control procedures throughout manufacturing, packing and release.
Depending on the product and agreed requirements, these controls can include raw material checks, in-process capsule weight checks, visual inspection, capsule polishing, metal detection and finished product testing.
G&G operates to recognised manufacturing and food safety standards, including MHRA GMP and FSSC 22000. More information about our standards, cleanroom and quality procedures is available on our quality control page.
Bulk and Retail Packing Options
We can supply manufactured capsules in bulk for customers who have their own packing arrangements, or pack them into finished retail packaging.
Our established packaging options include PET and HDPE containers and amber glass jars. Label application, induction seals and desiccants can also be considered where appropriate.
If you have a different packaging requirement, our team can assess its suitability for your product and production run.
Our Capsule Manufacturing Process
1. Tell us about your product More
Provide information about your business, target market, proposed formulation, capsule count, packaging requirements and intended sales market.
2. Choose White Label or Private Label More
Choose an established formulation from our White Label range or submit your bespoke specification for assessment through our private label service.
If you are unsure which route is most appropriate, our sales team can help you understand the differences.
3. Formula and ingredient review More
For Private Label projects, we assess ingredient availability, documentation, permitted use, dosage, capsule capacity and manufacturing feasibility.
We may recommend changes if an ingredient is unavailable, unsuitable for the intended market or unlikely to fit into the requested capsule format.
4. Quotation and product specification More
Once the manufacturing requirements have been established, we prepare a quotation based on the formulation, ingredient requirements, production volume and packaging.
The relevant product and order documentation will be provided for review and approval.
5. Approval and order placement More
The required specifications, order documents and artwork responsibilities must be agreed before production progresses.
Your account manager will explain what is required at each stage.
6. Ingredient sourcing and checks More
Approved raw materials are sourced from G&G’s supplier network or received from the customer where free issue materials have been accepted.
Materials must have the appropriate specifications and supporting documentation and pass G&G’s approval procedures before they can be used.
7. Capsule manufacturing More
The approved ingredients are prepared, blended and filled into the agreed capsule shell in our UK manufacturing facility.
Our encapsulation team selects suitable equipment based on the characteristics of formulation.
8. Quality control More
Capsules undergo the applicable in process and finished product checks. These can include capsules weight checks, visual inspections, capsule polishing and metal detection.
Testing and documentation are completed according to the product specification and agree requirements.
9. Packing and label application More
The capsules can be supplied in bulk or packed into the agreed retail format.
Where G&G is applying labels, print ready labels must be supplied in accordance with the relevant template and approval process.
10. Release and delivery More
Once the product has completed the required checks and has been approved for release, the finished goods are dispatched to the nominated delivery address.
White Label Capsule Supplements
Our extensive White Label range includes established capsule formulations across vitamins, minerals, botanicals, digestive support, active nutrition, collagen and specialist blends.
White Label offers a straightforward route to launching or expanding a supplement brand. You select the products you would like to sell, choose the appropriate capsule count and packaging, and provide your approved labels for application.
The product is then manufactured and packed under your brand.
All G&G White Label supplements are manufactured to order and are subject to our standard production lead times. Product specifications and samples can be requested through our sales team.
White Label may be suitable if:
- You want to launch an established supplement formulation
- You want a straightforward route to market
- You do not require a completely unique formula
- You want to concentrate on building your brand and customer base
- You want to expand an existing product range
Bespoke Private Label Capsule Manufacturing
Our Private Label service is designed for brands that want to manufacture their own bespoke capsule formulation.
You can approach us with a complete formulation, an existing product specification or an initial product. The formula will be reviewed to assess ingredient availability, permitted use, dosage, powder characteristics, capsule capacity and manufacturing feasibility.
We maintain an extensive ingredient database and work with trusted suppliers to source suitable raw materials. We may also accept customer supplied ingredients, provided they have the required documentation, pass our material approval process and are suitable for the proposed formulation.
Private label may be suitable if:
- You have your own formula or product specification
- You want to create a distinctive supplement for your brand
- You need particular ingredients or ingredient quantities
- You want to modify an existing product concept
- Your market positioning depends on formulation differentiation
The quantity of powder that can fit into a capsule depends on the density and characteristics of the ingredients. Where the complete serving will not fit into one capsule, it may need to be divided across two or more capsules.
We can also assess requirements such as vegan, vegetarian, organic, halal or kosher suitability. Final eligibility depends on the complete formula, individual ingredient documentation and the requirements of the relevant certifying organisation.
HPMC, Gelatine and Other Capsule Types
Hard capsules are available in different shell materials. The right choice depends on the formulation, dietary requirements, intended market and product positioning.
HPMC Capsules
HPMC capsules are made from hydroxypropyl methylcellulose and are G&G’s standard capsule option.
They are widely used for vegetarian and vegan supplements and are suitable for filling with many powdered ingredients. Their suitability for vegan, halal, kosher or other certified products depends on the shell specification, complete formulation and supporting documentation.
Hard Gelatine Capsules
Hard gelatine capsules are traditionally made using animal derived gelatine and are designed for filling with powders.
They remain suitable for many supplement formulations but are not appropriate for vegetarian or vegan products. Gelatine capsules can be considered on request.
Pullulan and Other Capsule Shells
Other shell materials, including pullulan, may be available for specialist applications. Availability and suitability depend on the product specification, required certification and production volume.
Please speak to our team if your product requires a particular capsule shell.
Capsule Sizes Available
Capsules are available in a range of sizes, commonly running from size 000, the largest standard size, to size 5, one of the smallest.
G&G commonly works with:
- Size 00
- Size 0
- Size 4
Sizes 00 and 0 are widely used for dietary supplements. Size 4 may be suitable for formulations requiring a much smaller quantity of powder, or for those having difficulty swallowing the larger sizes.
The weight of powder that fits into a capsule cannot be determined from capsule size alone. Ingredients have different densities, particle sizes and flow characteristics, so two powders of the same weight may occupy very different volumes.
Our team can assess whether your proposed formula is likely to fit into your preferred capsule size. If the serving is too large, it may be divided across multiple capsules or offered as a powder instead.
How G&G Fills Capsules Supplements
Capsules can be filled using manual, semi-automatic or fully automatic equipment.
Manual Capsule Filling
Manual capsule filling is generally used for development work, personal use and very small production runs. It requires significant manual input and is not normally efficient for commercial scale supplement manufacturing.
Fully Automatic Capsule Filling
Fully automatic equipment can produce very large quantities of capsules quickly. However, the powder must flow consistently through the machinery.
Many formulations may require flow agents or other processing aids to maintain production speeds and filling consistency.
Semi-Automatic Capsule Filling
Semi-automatic machinery combines mechanical filling with input from trained operators. This approach can provide greater control over formulations with challenging powder characteristics.
G&G uses semi-automatic capsule filling machines as part of our Trufil® manufacturing method. Our experienced operators can adjust the process according to the properties of the powder and select from different machines to find the most suitable option for the formulation.
This approach allows us to manufacture many capsule products without standard excipients such as magnesium stearate. Every formula remains subject to a technical feasibility assessment.
Benefits of Capsule Supplements
Capsules are a popular supplement format because they offer considerable formulation flexibility and convenience.
Flexible Formulations
A wide range of powdered vitamins, minerals, botanicals, amino acids and other suitable ingredients can be encapsulated, subject to regulatory, technical and capacity requirements.
Different ingredients can be combined into a single formulation, while larger servings may be divided across two or more capsules.
Suitable for strong tasting ingredients
The contents of a hard capsule do not normally come into direct contact with the tongue.
This makes capsules useful for ingredients with strong, bitter or otherwise unpleasant flavours. In comparison, drink powders may require flavouring and sweetening to create an acceptable consumer experience.
Convenient, pre-measured servings
Capsules provide consumers with a consistent, pre measured serving. They are portable, easy to store and convenient to take away from home.
Unlike powders, they do not normally require a scoop, shaker or mixing instructions.
Suitable for clean label products
Hard capsules do not require the same compression process or type of binders used to hold tablets together.
G&G’s Trufil® process allows many formulations to be manufactured without standard flow agents such as magnesium stearate, supporting brands seeking straightforward, clean label ingredient lists.
Vegetarian and Vegan Options
HPMC capsules provide a widely used alternative to animal derive gelatine shells and can be suitable for vegetarian and vegan formulations.
The complete product must still be assessed to confirm that every ingredient and process material meets the relevant requirements.
When is a powdered supplement more suitable?
Capsules are not suitable for every formulation.
Where the required serving contains several grams of ingredients, dividing it across capsules may create an impractical daily serving. In these situations, a powder supplied in a tub or stand up pouch may be more suitable.
G&G manufactures both hard capsules and flavoured or unflavoured supplement powders. Our team can help assess which format is more appropriate for your product.
Capsule Manufacturing FAQs
What capsule sizes can G&G fill? More
G&G Vitamins commonly fill size 00, size 0 and size 4 capsules. The most suitable size depends on the quantity and density of the ingredients in your formulation.
Can G&G manufacture vegan capsule supplements? More
Yes. HPMC capsules can be suitable for vegan products. The complete formula and supporting ingredient documentation must also meet the relevant vegan requirements.
Can I supply my own ingredients? More
Yes, subject to approval.
Customer supplied ingredients must have the required specifications and supporting documentation, comply with the applicable legislation and pass G&G’s material approval process. We may also request a sample before confirming suitability.
Let us know as early as possible if you would like to supply your own ingredients.
Can G&G source ingredients for my capsule formulation? More
Yes. We have established relationships with trusted suppliers and source the majority of ingredients used in the supplements we manufacture.
Ingredients availability, order quantities, documentation and permitted use will be reviewed as part of the private label process.
Can capsules be manufactured without magnesium stearate? More
Yes. Our Trufil® method allows us to manufacture many capsule formulations without standard excipients such as magnesium stearate or microcrystalline cellulose.
Every formulation is assessed individually to confirm whether excipient free production is technically feasible.
What happens if my formula will not fit into one capsule? More
The serving may be divided across two or more capsules.
For formulations requiring a particularly large serving, a powder may be more practical. Our team can assess capsule capacity during the feasibility review.
Can G&G package the capsules? More
Yes. We have dedicated packing an label application facilities for a range of packaging formats.
Available options include PET and HDPE containers and amber glass jars. Induction seals and desiccants can also be considered where appropriate.
Can capsules be ordered in bulk? More
Yes. We can supply manufactured capsules in bulk if you have your own approved packing arrangements.
Tell our team that you require bulk capsules when submitting your enquiry.
Can G&G manufacture organic capsule supplements? More
G&G is certified by the Soil Association to manufacture organic supplements.
Although permitted capsule shells may not themselves be certified organic agricultural ingredients, approved HPMC shells can be used in qualifying organic product. Eligibility depends on the complete formulation and Soil Association requirements.
Can you manufacture halal or kosher capsule supplements? More
We can assess halal or kosher requirements as part of the project review.
Suitability depends on the capsule shell, every ingredient in the formulation, the available supporting documents and any certification required for the finished product.
G&G has been assessed by relevant organisations to be permitted to manufacture halal and kosher within our premises, but each product needs to be assessed individually before they can be sold with these claims.
Do you manufacture tablets or softgels? More
We do not manufacture tablets or softgels at our facility.
G&G specialises in hard shell capsules and powders. Selected sourced softgel products are available through our White Label range.
Do you manufacture capsules for start up brands? More
Yes. We work with start ups as well as established supplement businesses.
If you are new to the industry, our start up guide explains the main decisions involved in choosing a product, manufacturing route, packaging and route to market.
How do I request a capsule manufacturing quotation? More
You can submit a quotation request through our website, call us on 01342 311401 or email hello@gandgvitamins.com
Provide as much information as possible about your formula, required capsule count, packaging, anticipated order quantity and intended sales market. This will help our team assess your enquiry effectively.
Get a Quote
Whether you want to choose an established White Label product, manufacture a bespoke formula or order filled capsules in bulk, G&G can help you identify the right route.
Tell us about your capsule project and a member of our new business team will be in touch to discuss your requirements.