New solutions for nutraceuticals.

Authors Stefano Biserni, Product Manager for Capsule Fillers at IMA Active Stefano Crivellaro, Capsule Filling Technologist at IMA Active Fabriano Ferrini, Product Manager for Capsule Fillers at IMA Active Alessio Tarozzi, Product Manager for Capsule Fillers at IMA Active

1. Introduction

Nutraceutical products are predominantly delivered in capsule form by the time they reach the consumer market.
Filling capsules with powders using the tamping pin method is a well-established technology, and many producers have simply grown accustomed to the challenges it presents.

Often, they are unaware of alternative solutions that could significantly improve the performance and efficiency of their production lines.

With the right technological approach — and a supplier who understands the characteristics of the powders being handled — it is possible to achieve:

• Consistent filling
• Precise dosing
• Fewer rejects
• Optimised production costs

2. The growing trend for nutritional supplements

Since the early 2000s — and especially after the pandemic — demand for nutritional supplements has surged.

Beyond performance-boosting products for athletes, consumers are increasingly focused on prevention over treatment, driving interest in:

• Probiotics
• Mineral and vitamin supplements
• Natural products that support the immune system

At the same time, consumers are becoming more selective, often preferring natural ingredients and zero excipients.

In the rush to meet demand, some manufacturers compromise on raw material quality and consistency, which can lead to:

• Processing difficulties
• Unwanted waste
• Avoidable downstream costs

While bulk powders are easy to obtain, processing them efficiently — especially when they vary in behaviour — is not straightforward with basic machine technology.

With nearly 60 years of experience in the pharmaceutical industry, IMA has developed technologies capable of handling a wide range of powders, with or without excipients.

Today, that expertise — supported by a vast database of processing parameters — is available to the nutraceutical industry.

3. A closer look at the demands of the industry

The nutraceutical sector is highly attuned to consumer expectations.

Key priorities include:

• Maximising product content per capsule
• Using natural, plant-based capsule materials(e.g. HPMC, modified starch)
• Ensuring consistent capsule weight
• Achieving high production efficiency with minimal waste

These goals are attainable — especially with a technology that’s gaining market share thanks to its ability to address common challenges, such as:

• Variability in powder quality and flowability
• Inconsistent capsule characteristics
• Downtime between production batches

So what makes this technology different — and how does it improve output and quality?

4. For each issue, a technological solution

Powders used in nutraceuticals vary widely:

• Some are sticky, others highly flowable
• Carr index values can differ significantly

Tamping pin-type capsule fillers struggle when flowability is poor, as gravity alone cannot ensure consistent powder dosing.
This leads to inconsistent slugs and capsule weights.

In contrast, the standard configuration of an intermittent capsule filler (with rotating bowl and dosators) can handle even complex powders with diverse characteristics.

When needed, IMA capsule fillers offer an exclusive feature: the suction bowl.
This system:

• Removes excess air from the powder mixture
• Increases powder density
• Creates a pre-compacted layerready for dosing

The result: each slug contains a consistent quantity of product throughout the batch.

When flowability is too high, powders may escape the dosator — especially in continuous-motion machines.
IMA’s alternating motion system solves this by:

• Temporarily retaining the powder using vacuum aspiration
• Rotating the dosator to release the slug into the capsule

This ensures no powder loss and uniform fill weight across the batch.

Even powders with poor flowability — and those formulated 100% pure, without excipients or binders — can be processed effectively.

As shown in the application data (Table 1), it is possible to operate at maximum speed, within target weights and tolerances, by optimising:

• Powder layer height
• Chamber height
• Compression parameters

Table 1: application data

5. Maximum flexibility and high-speed processing

Producers of nutraceuticals gain two major advantages with IMA capsule fillers:

1. The ability to handle a wide variety of powder types
2. The capacity to run at high production speeds

The technology is easily adaptable. Key parameters can be adjusted via an intuitive HMI, allowing quick reconfiguration — especially useful for small batches or frequent dose changes.

For example:

• Dose adjustmentscan be made in minutes
• Capsule format changesrequire no alignment tools, thanks to Poka-Yoke-designed parts

In contrast, tamping pin machines often require:

• Alignment tools
• Complex assembly
• Up to 8 hours for format changes

Cleaning operations are also faster with IMA solutions, reducing downtime between batches.

Performance also means speed. IMA has a strong track record in nutraceutical capsule filling, with most customers running at full speed.
No recorded case has operated below 75% of machine capacity.

6. Greater efficiency, better quality, reduced costs.

The technology developed by IMA delivers measurable benefits:

• Optimised powder contentper capsule
• Precise and consistent filling
• Adaptabilityto raw material variability
• Minimal rejects
• Faster changeovers and cleaning

Over time, this translates into:

• Fewer capsules wasted
• Lower production costs per unit
• Higher output and product consistency

And ultimately, a better product — one that consumers will continue to choose.