Smooth capsule, tablet, and gummy supplement production

Key takeaways
              Nutraceutical manufacturers face increasing complexity and demand and must select the right dosage form for their product
Syntegon provides integrated solutions for the entire supplement lifecycle – from raw material processing to finished products
Capsules, tablets, and functional gummies each offer distinct advantages in terms of ingredient protection, scalability, cost efficiency, and consumer acceptance
High precision and automation improve product quality, reduce rejects, and increase OEE across all dosage forms
End-to-end lifecycle support – from formulation and testing to scale-up and maintenance – helps manufacturers ensure operational reliability and respond to market changes

            

Whether it’s tablets and capsules or functional gummies, nutraceuticals are a globally growing market driven by fast-moving trends like demand for clean-label ingredients or supporting gut health. For manufacturers, matching this demand and need for flexibility is a constant challenge. Moreover, they need to decide on the best possible dosage form for their product to be successful in a competitive environment. Consumer habits, production requirements and the characteristics of natural ingredients all need to be considered, as sticky botanicals, hygroscopic powders, and sensitive oils can derail formulation or clog product paths. Syntegon supports your supplement from raw ingredients to finished product: Our extensive services guide you in your decision on the right dosage form, developing the formulation or recipe for your product and ensure your nutraceutical equipment from Syntegon reliably delivers on efficiency, flexibility, and quality at every step.

Read below which dosage form is best for your product and unique production needs – or get in touch with our experts for an in-depth consultation.

Discuss your formulation and process goals Get an overview of our portfolio & services

Ginkgo powder, pellets, and capsules illustrating different nutraceutical dosage forms.

Supplement capsules filled with precision

The ideal supplement form depends in no small part on the ingredients. Many nutraceutical powders – sticky, waxy, or particularly sensitive materials – are hard to compress. In these cases, capsules are the ideal solution as they maintain the integrity of the sensitive materials best. Our comprehensive portfolio for supplement capsule production includes vital upstream solutions like high-shear mixers and fluid bed systems for drying, granulating, and pellet coating. They create homogenous granules, powders, or pellets for further processing.

Syntegon’s capsule fillers have elevated our production to new levels of precision and efficiency. Natural supplements now exceed quality expectations, downtime is significantly reduced, and we’re capable of running beadlets with Syntegon’s slide gate technology.

Joaquin Báez, Director of Operations, Florida Supplement

Our GKF Capsylon series was developed for the nutrition and health industry and fills a wide range of gelatin or HPMC capsules with exceptional precision thanks to tamping pins and our patented slide-gate technology. At the same time, it is easy-to-operate and highly efficient. For extra flexibility, it also features combination filling. The Syntegon GKF series for liquid filling is particularly suited for products like omega-3-rich oils and handles viscosities from oil to paste and wax. Its “no cap no fill” function reduces rejects, while automated troubleshooting (ASB) increases OEE and yield. Both series can be equipped with our KKE Nutra series checkweighers to ensure maximum dosing precision. Optional capsule sealing adds tamper-evidence, prevents leakage in liquid-filled capsules, and with up to 125,000 capsules per hour our Syntegon GKB 2100, does not slow down production.

Capsule filling – your benefits at a glance
              Optimum protection of natural ingredients
High efficiency – through short changeovers, cleaning times, and Automated Process Development (APD) to determine optimal parameters quickly
Flexible, easy operation – with good access to all parts and a wide ingredient and capsule size range

            

White nutraceutical tablets arranged around a cannabis leaf.

Nutraceutical tablets for any output

Are you aiming for a higher active ingredient concentration? Then supplement tablets might be the right solution. While not suitable for every raw material, tablets can also typically be produced at higher output and lower cost per-unit. Building on the same upstream equipment of high-shear mixers and fluid bed systems, our TPR series presses your nutraceutical powders into tablets and covers the full range: From the compact TPR 200 Plus for small to medium batches to the high-performance TPR 700 for large volumes at speeds of over one million tablets per hour. They combine high flexibility and easy operation with hygienic concepts that reduce cleaning and maintenance effort while enabling a variety of product options like bi-layer or effervescent tablets.

For coating your supplement tablets, we offer scalable solutions ranging from the Solidlab systems for R&D and small batches to the Sepion coater for large-scale production. They deliver precise and uniform coatings for taste masking, enteric protection, or active ingredients, while ensuring short process times and efficient, automated cleaning.

Tablet compression & coating – your benefits at a glance
              High scalability – from R&D batches to large-scale production with consistent quality
Efficient operation – high output and easy cleaning thanks to organized machine tables, fast format and turret exchanges
Flexible lines – suitable for a wide range of formulations and coating requirements

            

Hygiene, accuracy, and great taste for functional sweets

As the unarguably most pleasant-tasting dosage form, functional gummies are an increasingly popular, widely accepted way especially among younger consumers to fill their nutritional needs. With our turnkey solutions for cooking, depositing (starchless or starchbased), cooling, and product finishing, your functional sweets will turn out consistent in shape, weight, and texture with a high-quality finish.

Our high-performance Mogul lines are designed for starchbased depositing, while our turnkey line Makat NutraFlash features a completely starchless depositing technology. NutraFlash is especially well-suited for nutraceutical production and manages every stage of the process – from dosing and mixing ingredients to finishing. At the heart of the NutraFlash kitchen, the Rapidsolver Solids+ dissolves the base jelly mass with a particularly high dry substance content of up to 86 percent, thus eliminating the need for moisture removal through starch and making production both gentler and faster. Within the NutraFlash line, the CMP tailless depositor subsequently distributes even highly viscous jelly masses into starchless, reusable molds. After cooling in the integrated tunnel, the BC 96 oiling drum applies the finishing touches while a continuous condition monitoring ensures that the production runs smoothly along the entire line.

Functional sweets production – your benefits at a glance
              High yields – accurate recipes, precise depositing, and gentle handling lower reject rates
Turnkey simplicity – harmonized processes, a consistent control system, and one seamless line make production simple
Reliable support – from recipe development to testing and refining your production processes

            

Your partner for the supplement lifecycle

To succeed in the nutraceutical market, manufacturers and CMOs need the ideal dosage form for their product and equipment that reliably combines flexibility, quality, and efficiency. Syntegon supports you every step of the way: Our nutraceutical lifecycle services bring decades of hands-on experience that allows experts in our dedicated competence centers to guide you in defining the right formulation and dosage form for your product. Our field and technical services ensure your machines stay up and running, supply you with important spare parts right on time, or train your operators.

As your lifecycle partner, we provide tailored solutions designed to grow with your business. From initial testing and technical transfers to scale-up support, our team is with you at every stage. We help minimize downtime through rapid troubleshooting and reliable spare parts delivery, while keeping your production future-ready with the latest updates and upgrades. The result? Equipment precisely matched to your product, the agility to respond to shifting market demands, and a lasting competitive edge. Whether you are looking to enter the supplement market or take your existing production to the next level, we are here to make it happen.

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Nutra services flyer

Explore gummies, tablets and capsules plus the process and service support behind them. Use it to compare dosage forms, scale paths and lifecycle options.