Capsule-based supplements remain one of the most popular and versatile formats in the UK market. At Nutribl, we help brands and private label clients develop custom capsules that are legally compliant, functionally effective, and commercially viable.

If you're considering launching your own capsule product, here’s what you need to know — including critical packaging cost implications that can affect your budget and MOQ.

1. Product Definition: Know What You Want

Before diving into development, get clear on the basics:

• Target Function: Sleep, Immunity, Digestion, etc.
• Daily Dose: One-a-day? Two capsules twice daily?
• Format: Standard capsules (vegan/hard gel), delayed-release, or combination dosing?
• Hero Ingredients: E.g. Ashwagandha, Vitamin D, Turmeric, L-Theanine
• Capsule Size Preference: Size 0, 00, or custom (based on actives)

A well-defined brief reduces cost, speeds up R&D, and ensures regulatory accuracy from the start.

2. Regulatory Screening: What’s Legal?

Nutribl enforces strict UK-only ingredient vetting, using:

• UK Novel Food Catalogue
• Annex II – Permitted Vitamin & Mineral Forms
• MHRA Borderline Product Guidance
• Food Supplements (England) Regulations 2003

We’ll flag and reject any ingredient that is:

• Not listed in approved registers
• A highly standardised extract (>10:1, 95% actives)
• From unclear sources (e.g. synthetic L-Theanine)
• Described or presented with medicinal intent (e.g. "cures anxiety")

This keeps your capsule legally marketable in the UK — essential for both retail and e-commerce sales.

3. Capsule Formulation: Function vs Fill

Capsule formulation focuses on:

• Active Ingredient Load (what you want to include)
• Excipient Selection (what you need to make it fill, flow and blend correctly)
• Capsule Size (based on total bulk density)

⚠️ Too many actives = large capsule or multi-capsule daily dose
⚠️ Too few actives = risk of under-filling or requiring excessive excipients

We work to balance efficacy with capsule practicality and label integrity.

4. Packaging Matters – Bottles vs Pouches

One of the most misunderstood cost drivers in capsule NPD is packaging — especially when clients request pouches.

Bottles (Standard Option)

✅ Low MOQ (as low as 60,000 capsules / 1,000 units)

✅ Off-the-shelf sizes (30, 60, 90, 120 count)

✅ Can use low-cost (but great looking) printed labels

✅ Easy for shelf display and protective for capsules

Pouches (Looks Great, But…)

⚠️ Very high MOQ if pre-printed (often 5,000–10,000+ per SKU)

⚠️ Print setup costs (£300–£600 per design/variant)

⚠️ Limited sizes with good oxygen/moisture barriers

Pouches only become cost-effective at scale. For smaller launches or test runs, bottles with printed labels are usually more viable. There is more information specifically about pouches in our article The Pros and Cons of Using Pouches for Food Supplements

5. NPD and Launch Costs

For capsules most of the development is done in the product concept - after that we will make to specification.  Our NPD service for capsules is £295 and can be ordered here. We will provide:

• Formula Development (based on your brief)
• Regulatory Audit
• Marketing & Health Claim Utilisation
• Advisory Labelling 
• Finished Product Compliance Report

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Once the formula is agreed we will quote and, if accepted, will schedule production with an expected lead time of 6-10 weeks.

Summary: What to Budget and Plan

When engaging on a custom capsule project, unlike powders, the development phase is relatively straightforward. The NPD and compliance element is covered by our NPD service fee - £295 per product - https://www.nutribl.com/p-1075-new-product-development-service-capsules-and-tablets.aspx

Once a formula, packaging and unit count is agreed we can quote. Without knowing what is going into a supplement it is impossible to know the final cost as the ingredient cost is the most variable factor. High-potency extracts, branded ingredients (e.g. KSM-66), or complex formulas can increase total cost of goods substantially. 

As a rough guideline, based on an MOQ of 60,000 capsules and packed into 60s (1000 units) you might expect the capital investment requirement to be anywhere from £4,000-£10,000 per product. This ranges are not absolutes and could be heavily influenced by factors such as:

• Analytical testing (heavy metals, micro, actives): £150–£350 extra (if requested)
• Cartons: Add £0.35–£0.75 per unit if included
• Pre-printed pouches: Minimum 5,000–10,000 units + £300–£600 print plate/setup fees
• Branded or trademarked actives: Higher cost per mg/dose

Ready to Launch Your Capsule Product?

Capsules remain the most scalable format for supplements — and the most versatile across markets. Whether you're developing a clean-label calming blend or a complex multivitamin, we’ll ensure it's legally sound, label-ready, and commercially viable.