Filling capsules by hand is how most small supplement brands, herbal practitioners, pharmacy compounders and research labs get started. With a simple manual capsule-filling machine and a little practice, you can fill hundreds of empty hard gelatin capsules in a few minutes, with consistent weights. This guide walks you through it step by step.
The short answer
Load empty capsules into a manual filling machine of the matching size, lift off the caps, spread your powder over the bodies, scrape and tamp until they are evenly full, then put the caps back on and press to lock them. Work in a clean, dry room, and check the weight of a sample of filled capsules before you fill the whole batch.
What you need
Empty hard gelatin capsules
Choose the size that holds your dose. Sizes 0 and 1 are the most common for hand filling. Our size chart shows how much each size holds.
A manual capsule filler
These range from small 24-hole hand fillers to 100-hole and larger manual machines. The plate must match your capsule size exactly.
Your powder blend
Dry, free-flowing and evenly mixed. Lumpy or damp powder fills unevenly.
Small tools
A plastic scraper or card, the tamper that comes with the machine, a digital scale reading to at least 1 mg, and disposable gloves.
Before you start
Work on a clean, dry surface, away from fans, open windows and steam. Gelatin capsules behave best at about 15 to 25 °C and 35 to 65 percent relative humidity. Below about 30 percent the shells turn brittle and can crack; above about 65 percent they soften and stick. Wear gloves so the shells stay clean and dry.
Weigh your total blend and work out the fill weight you need per capsule. If you are not sure which size fits, measure the bulk density of your powder (weigh a known volume, for example 100 mL) and compare it with the table below.
| Size | Volume | At 0.6 g/mL | At 0.8 g/mL |
|---|---|---|---|
| 00 | 0.90 mL | about 540 mg | about 720 mg |
| 0 | 0.68 mL | about 408 mg | about 544 mg |
| 1 | 0.48 mL | about 288 mg | about 384 mg |
| 2 | 0.36 mL | about 216 mg | about 288 mg |
| 3 | 0.27 mL | about 162 mg | about 216 mg |
Step-by-step: filling capsules with a manual machine
1. Load the empty capsules
Pour a handful of empty capsules onto the loading tray and gently shake it from side to side until a capsule drops into every hole, cap side up. Tip off the extras and check that no hole is empty or holds a capsule upside down.
2. Separate the caps
Place the cap plate on top, press lightly so it grips the caps, then lift it straight up. The caps come away and the bodies stay standing in the base. Set the caps aside on the plate without tipping them out.
3. Spread the powder
Pour some of your blend onto the bodies and spread it evenly with the scraper, working it into every body from several directions.
4. Tamp and top up
Use the tamper to press the powder down gently, then spread more powder over the top. Repeat until every body is evenly full. Do not press too hard; over-tamping can dent the shells or make them hard to close.
5. Scrape the surface clean
Draw the scraper across the plate to remove loose powder so the rims of the bodies are clean. Powder on the rims stops the caps from locking properly.
6. Replace the caps and lock
Put the cap plate back in place, lining it up with the bodies, then press down firmly and evenly until you feel the capsules click shut. Release the filled capsules from the machine.
7. Check the weights
Weigh 10 to 20 filled capsules one by one. Subtract the empty shell weight (about 99 mg for size 0 and 78 mg for size 1) to get the fill weight, and compare it with your target. Adjust your tamping if the weights are low or uneven.
8. Clean and store
Wipe or gently tumble the filled capsules in a clean cloth to remove dust, then store them in an airtight container away from heat, light and humidity.
Tips for better results
Keep everything dry. Moisture is the main cause of sticky powder and soft shells. Mix thoroughly. An even blend gives even capsules. Use a light hand with the tamper. Several gentle passes fill more evenly than one hard press. Keep a log. Note the capsule size, blend weight and number of capsules for each batch so you can repeat it exactly. If your capsules crack, stick or open after filling, see our guide to common capsule filling problems.
Frequently asked questions
How long does it take to fill 100 capsules by hand?
With a 100-hole manual machine and a little practice, one plate usually takes a few minutes from loading to locking.
Can I fill capsules without a machine?
Yes, by opening each capsule and scooping powder in by hand, but it is slow and the weights vary a lot. Even a small manual filler gives far more consistent results.
Which capsule size is easiest to fill by hand?
Sizes 0 and 1 are the easiest to handle. Very small sizes are fiddly, and size 000 is often uncomfortable to swallow.
Why won't my capsules close properly?
Usually because they are overfilled or there is powder on the rims. Scrape the plate clean and tamp less before closing.
Need empty capsules for hand filling?
Universe Capsules manufactures empty hard gelatin capsules in plain, printed, metallic and pearl finishes. Tell us the size and colour you need and we will send samples.
Request samples
