The capsule formula fueling steady growth

Apr 20, 2026 | 2 min read

Working with Syntegon, ABJ alive was able to significantly increase efficiency and reduce downtime despite filling challenging ingredients into capsules. The partnership lays the foundation for meeting market demands in a flexible and scalable manner.

Key takeaways
              20% less downtime with GKF Capsylon capsule filling machines
Up to 50% higher efficiency handling challenging ingredients such as magnesium oxide
High flexibility for changing formulations and complex ingredients
Co-create to co-succeed: long-term partnership on equal footing strengthens scalability and growth

            

The market for nutraceutical capsules is growing rapidly. New products, sensitive active ingredients, fast-moving trends, and rising demands for quality and speed are increasing production complexity. Manufacturers and Contract Development and Manufacturing Organizations (CDMOs) must reliably process a wide variety of formulations while responding flexibly to new market demands.

ABJ alive: Growth under challenging conditions

ABJ alive (a member company of 1Q Health), based in Creußen, specializes in the development and manufacture of nutraceutical capsules. The company uses a broad spectrum of ingredients – from vitamins and minerals to probiotics and plant extracts. Many of these raw materials are challenging to process, for example due to their sensitive structure or varying material characteristics.

Watch ABJ alive’s growth story

From trial run to long-term partnership

To meet rising demand and complex requirements, ABJ alive has relied on Syntegon’s GKF Capsylon series since 2018. What began as a test project with a single machine evolved into a long-term collaboration spanning the entire lifecycle of the machine. Today, the company operates a total of six high-performance capsule fillers, enabling it to produce large batches efficiently and reliably. The decision proved to be the right one, as its success shows: Sales have since risen by around 40 percent.

“Since we started using Syntegon technology, we’ve experienced about 20 percent less downtime and have also been able to increase product yield.”

Dr. Florian Geppert, Plant Manager at ABJ alive

Compared to previously used systems, the technology enables higher output while reducing downtime. Easy operation and fast cleaning also support smooth production processes and short changeover times.

Slide-gate: patented technology for demanding formulations

A key success factor is the patented Syntegon slide-gate technology. It ensures particularly gentle and precise dosing of a wide variety of raw materials and reduces product losses. At the same time, dust impact on the machine is minimized, which increases process stability and allows ABJ alive to process pellets at the same dosing station.

“Since using the slide-gate technology, our efficiency for magnesium oxide has increased by up to 50 percent.”

Dr. Florian Geppert, Plant Manager at ABJ alive

Shaping the Future Together

The collaboration between ABJ alive and Syntegon goes beyond mere equipment – it combines application-specific know-how with technological expertise and lays the foundation for continuous optimization. “We want to double our output in capsules and will certainly need more machines from Syntegon to reach our goals in the future,” says Dr. Geppert.

ABJ alive is thus ideally positioned to achieve further growth – and the co-creation with Syntegon remains key to this.

Experience our solutions for nutraceutical capsule production at Vitafoods