Your formula as finished capsule supplements, ready to sell under your brand.
For supplement brands launching a new product, moving an existing formula or planning repeat batches. One partner sources the raw materials, fills the capsules, packs them in jars or blisters and labels them in our own factory in Komenda, Slovenia, so you coordinate one supplier instead of several.
- Finished packs
- MOQ 1,000 units per product in jars or blisters. Lead time: ready to ship 60 calendar days after your approved specification, label artwork and deposit are in place.
- Bulk capsules
- From 300,000 capsules per product, usually around 60 days, ex works Komenda.
Written offer within 1 to 3 business days.
Selling in the UK? See how ordering works for UK brands.
Start with the capsule shell.Fill the body with the prepared blend.Close the capsule, then pack the product.
- Capacity for launch and repeat orders: 11 capsule filling machines, 400+ million capsules filled in 2026.
- Documented quality: a COA for every raw material, production under GMP for food supplements and HACCP from Bureau Veritas.
- The format your channel needs: finished jars or blisters with your label, or bulk capsules for your own packing line.
FDA registration is a filing, not FDA approval.
Built around production of capsule supplements
Capsule supplements are the core service. Softgels are made here too and packed in jars only. Tablet and powder projects can also be discussed on request; gummies and liquids are outside our manufacturing range. The size and volume examples below explain capsule selection and do not confirm every format for production.
Bring the formula, fill and pack into one specification
TS LAB fills and packs hard capsules for supplement brands at its own site in Komenda, Slovenia. The service connects the materials and capsule specification to packaging and the documents agreed for your order.
Blending
Your formulation is weighed and blended into a uniform powder mix, batch by batch.
Encapsulation
The blend is encapsulated in hard capsules, with the shell and size selected for the formulation and manufacturing requirements.
Packaging
Jar packaging in PET, HDPE and glass, plus blister packaging at the same production site. Select the container, count and protection requirements together.
Documentation
Raw-material COAs within the sourcing service, with finished-batch records, analysis and handover requirements scoped for the product.
Our packaging capability includes four jar lines and two blister lines. Available formats and production capacity are confirmed for your order.
Product briefs we can discuss: vitamins and minerals, herbal extracts, organic supplements, amino acids, probiotics, collagen and beauty products, omega ingredients, functional mushrooms, weight-management products, sports supplements, liposomal ingredients and larger-count marketplace packs. Suitability depends on the exact material and formulation. Explore the product categories.
Make the blend and capsule size work together
A hard capsule holds a defined volume. Ingredient concentration, blend density, flow and the intended serving size determine whether the proposed formulation is suitable.
Start with the material properties
Dry powders suitable for the filling process need an appropriate blend and flow behaviour. A denser blend can fit more mass into the same volume, but density alone does not establish manufacturability.
Identify fit and processing constraints
A high-volume dose, moisture-sensitive blend or difficult-flowing material may require changes to the formulation, shell or serving size. These need assessment before a production format is agreed.
Compare the available options
Options can include a different capsule size, another serving size or a suitable alternative ingredient grade. Any change needs assessment for the formula, label, pack and cost.
Confirm your exact formulation
Send the ingredients, grades and amounts for a product-specific assessment. A category name or generic fill-weight chart cannot confirm that a blend will run.
Understand the inputs to a capsule fit assessment
This guide explains how TS LAB checks capsule fit by fill weight. The calculator is an illustration; the manufacturing specification requires suitable material data and process assessment.
- 01
Start from the label
Identify the declared amount per serving and the intended capsules per serving. Include the complete formula, with excipients.
- 02
Account for concentration and overage
Convert the declared amount into the required quantity of each material using its nutrient share or concentration. TS LAB adds a manufacturing overage only for nutrients with an NRV, a vitamin or mineral with a reference intake.
- 03
Add up the powder per capsule
Divide each material’s quantity per serving by the capsules per serving. The sum is the powder each capsule has to hold.
- 04
Match the fill weight to a size
Each capsule size has a target fill weight. The smallest size that holds the powder is chosen and a filler tops it up to the target. Then assess the blend, filling process and available shell before fixing the capsule size.
Check your formula’s fill weight
Start with one ingredient and its amount per serving, then add more, up to six. Choose how many capsules make one serving to see the powder per capsule, the filler and the capsule size under the TS LAB fill rules. It is not a validated TS LAB formula or manufacturing approval.
The result, per capsule
The result is calculated in your browser from the TS LAB capsule data. Enable JavaScript to see it.
Fill weight by capsule size
Each bar compares the powder per capsule with the target fill weight of that size. Dotted values are assumptions for TS LAB to confirm.
How the calculator works
The calculator converts each declared amount to the mass of its source material with the nutrient share or concentration, adds the TS LAB manufacturing overage for nutrients with an NRV (none for other ingredients) and divides by the capsules per serving. It then picks the smallest standard capsule size whose target fill weight holds the powder, and a filler tops the capsule up to that target. It checks weight, not volume, because TS LAB sets capsule fills by weight.
Actual suitability depends on the material grades, blend properties and filling process. Bulk and tapped density are different measurements. Include the available material data in your enquiry so the assessment and any further work can be scoped.
To build the full formula, label and pack, continue in the Product & Label Studio.
What you send
Share the complete ingredient list, amounts per serving, intended capsules per serving and target markets. Add supplier specifications and density data if available.
Your formula determines the capsule size
Start with the amount you want to deliver per serving and how many capsules your customer will take. The complete blend determines the space those capsules need.
Allow for the full formula
The shell must hold the complete blend, including active ingredients and any excipients. Declared active amounts and total fill weight can differ.
Plan the capsules per serving
Splitting a serving across more capsules changes the fill needed in each one. Keep that trade-off in mind when planning your customer’s routine.
Use the actual blend data
Two formulas with the same weight can need different capsule sizes. Density and filling behaviour matter alongside the ingredient amounts.
Technical reference: fill weight, shell weight and bulk density
- Fill weight
- The total material inside one capsule, including active ingredients and excipients. It can differ from the declared active amount.
- Shell weight
- The mass of the empty capsule. It adds to the total capsule weight without increasing the amount of active ingredient inside.
- Bulk density
- The mass of powder per unit volume. Loose bulk and tapped density can differ, so supplier data should identify the measurement method.
The production specification should state the target fill weight and agreed tolerance.
Choose the shell for the customers you serve
Include your preferred shell material and any vegan or certification requirements in your brief. Material compatibility and available capsule sizes are part of the product decision.
| Material | What it means for your product |
|---|---|
| HPMC | A cellulose-based material used for non-gelatin capsule shells. Relevant when your brief calls for an alternative to animal-derived gelatin. |
| Gelatin | An animal-derived shell material. It is not suitable for a vegan product. |
Vegan certification covers more than the shell: the formula and relevant processing aids also matter. See vegan certification scope.
Filled and packed at the same factory
Capsule filling, jar packaging and blister packaging at our own production site in Komenda, Slovenia. Bring the formula and finished pack into one manufacturing brief.
Packing on your own line? We also supply filled capsules in bulk, in bags, for brands and contract packers. See bulk capsules.
From serving size to pack count
Set the capsules per pack from the serving size and the number of servings you want to sell.
Capsules per serving × servings per pack = capsules per pack
Get a quote for your product and quantity
Send your formula, preferred pack, capsule count and planned order quantity. Minimum quantities and pricing depend on the formulation and packaging requirements.
Get an offerDefine the evidence for your batch
Raw-material COAs, manufacturing certificates and finished-batch analysis have different scopes. Identify what your product, retailer or marketplace needs and agree the document list before production.
Manufacturing credentials to review
- GMP, good manufacturing practice, as a certified production standard
- HACCP, certified through Bureau Veritas
- Organic product handling
- V-CERT for certified vegan products
- Facility registration with the US Food and Drug Administration
Your product’s document scope
Confirm the required records, tests, issuer, format and issue timing in the order. Additional analysis should have an explicit scope and cost.
The documents pageContract manufacturing questions
Which capsule sizes do you fill?
The page shows reference sizes to explain fit. The available shell and size for your product must be confirmed against the formulation, material data and manufacturing requirements.
Do you use vegetable HPMC or gelatin shells?
Confirm the available shell material and size in your product specification. If you require a vegan product, assess the complete shell, fill and process against that requirement.
How do you decide which capsule size my formula needs?
The assessment considers formula quantities, ingredient concentrations, blend density, serving size and processing suitability. The calculator illustrates the fill-weight check; the final choice requires product-specific assessment.
How much active ingredient can one capsule hold?
It depends on the material concentration, excipients, blend density and shell volume. There is no single active-ingredient weight that applies to all formulas in a capsule size.
What is fill weight and what is shell weight?
Fill weight is the material inside the capsule. Shell weight is the empty capsule. Their combined weight does not by itself tell you how much of each active ingredient is present.
What do you not fill?
Suitability is confirmed for the exact formula and physical form. Capsules are the core service; we also make softgels, packed in jars only. Tablets and powders can be discussed on request. Gummies and liquids are outside our manufacturing range.
What is your monthly capacity?
TS LAB publishes capacity figures of over one million units and over two million blister packs per month. These are company-published figures, not a confirmed allocation for your order. Share the quantity and timing required to assess available capacity.
What does a capsule suitability assessment include?
The scope depends on the available formula and material data. Ask which checks, trials and reports are included and whether a fee applies. The on-page calculator is available to explore the arithmetic without placing an order.
Send the formula behind your next supplement batch
Include the serving size, quantity, target market and preferred pack. Receive a written offer within 1 to 3 business days.
Capsule filling and packing at our own EU production site. Explore the Komenda factory.