Learn how to read and use a Capsule Size Chart to choose the right capsule for your formulation. Compare sizes 000–5, capacity, weight, volume, and equipment compatibility for pharmaceutical and supplement manufacturing as per cGMP.

The Complete Guide to the Capsule Size Chart (000 to 5)

Choosing the correct capsule size is one of the most important decisions in pharmaceutical, nutraceutical, and supplement manufacturing. A Capsule Size Chart serves as a practical guide that helps formulators select the ideal capsule based on dosage, volume, density, and production requirements.

From size 000 (the largest) to size 5 (the smallest), each capsule size offers a different capacity and swallowing experience. Selecting the right one directly affects dosage accuracy, product effectiveness, patient compliance, and even manufacturing efficiency.

If you are developing capsules, understanding how to properly read and apply a Capsule Size Chart isn’t optional—it’s essential.

Capsule Size	Approx. Volume (ml)	Approx. Weight Capacity (mg)	Empty Capsule Weight (mg)	Closed Length (mm)	External Diameter (mm)	Common Uses
000	1.37	950 – 1370	158	26.14	9.97	High dosage formulations, multiple active ingredients, often used in supplements and herbal products.
00	0.95	665 – 950	123	23.3	8.56	General purpose supplements, commonly used for moderate to high dosage formulations.
0	0.68	475 – 665	98	21.7	7.64	General purpose supplements, widely used for various formulations including vitamins and minerals.
1	0.5	350 – 475	76	19.4	6.91	Lower dosage supplements, often used for targeted or specialized formulations.
2	0.37	250 – 350	61	17.5	6.35	Moderate dosage supplements, suitable for pediatric or geriatric populations.
3	0.3	200 – 300	48	15.9	5.85	Small dosage supplements, often used for sensitive populations or small animals.
4	0.21	150 – 200	38	14.3	5.33	Very small dosage, suitable for highly concentrated formulations or sensitive populations.
5	0.13	100 – 150	28	11.1	4.91	Very small dosage, typically used for microdosing, pediatric, or pet products.

Why a Capsule Size Chart Matters

A Capsule Size Chart provides detailed specifications about capsule dimensions, capacity, and tolerances. These details ensure:

Accurate dosage delivery
Proper filling without overfilling or underfilling
Equipment compatibility
Consumer-friendly swallowing size
Regulatory and quality compliance

For example:

Size 000 holds the highest volume (up to ~1,370 mg depending on density) but may be harder to swallow.
Size 5 is the smallest and easiest to swallow but holds a much smaller dose.

Balancing capacity and comfort is key, and the Capsule Size Chart helps you achieve that balance.

How to Read a Capsule Size Chart

At first glance, a Capsule Size Chart may look technical. However, once you understand the components, it becomes an invaluable formulation tool.

Here are the key elements typically included:

1. Capsule Sizes (000 to 5)

Capsules are numbered from largest (000) to smallest (5). Each size has unique dimensions and filling capacity.

2. Weight Capacity (mg)

This shows how much material a capsule can hold in milligrams. Capacity depends heavily on material density. For example:

Size 00 may hold around 735 mg (depending on density)
Size 4 may hold around 120 mg

3. Volume Capacity (mL)

This refers to the internal volume of the capsule. It helps determine how much space your formulation will occupy and prevents spillage or underfilling.

4. Empty Capsule Weight

The weight of the empty shell is important for calculating total fill weight and ensuring precise dosing.

5. Overall Closed Length (mm)

This measurement ensures the capsule fits packaging formats such as blister packs or bottles.

6. Body and Cap Length

The capsule body holds the material, while the cap seals it. These dimensions are helpful for equipment calibration.

7. External Diameter

Essential for packaging compatibility and machine alignment.

8. Tolerance Levels

Tolerance indicates acceptable dimensional variations, which is critical for quality control and regulatory standards.

By carefully reviewing these specifications, you can make informed formulation decisions.

Choosing the Right Capsule Size for Your Product

Selecting the correct size goes beyond simply fitting the formula inside.

You should consider:

Target audience (children, adults, elderly)
Required dosage
Ease of swallowing
Type of formulation
Manufacturing equipment

For example:

Pediatric or geriatric supplements often use sizes 3 or 4 for easier swallowing.
High-dose formulations may require size 00 or 000.

A Capsule Size Chart allows you to match dosage requirements with real-world usability.

Capsule Size	Low-Density Material (0.6 g/mL) Capacity	Medium-Density Material (0.8 g/mL) Capacity	High-Density Material (1.0 g/mL) Capacity
000	822 mg	1096 mg	1370 mg
00	570 mg	760 mg	950 mg
0	408 mg	544 mg	680 mg
1	300 mg	400 mg	500 mg
2	225 mg	300 mg	375 mg
3	180 mg	240 mg	300 mg
4	120 mg	160 mg	200 mg
5	75 mg	100 mg	125 mg

How Material Density Affects Capsule Size

The density of your formulation plays a major role in capsule selection.

Low-Density Materials

Plant powders and fibrous ingredients are bulky and light. They often require larger capsule sizes to reach the desired dose.

Medium-Density Materials

Standard pharmaceutical powders (~0.8 g/mL) usually fit well in sizes 0 or 1.

High-Density Materials

Minerals or metallic salts are compact and heavy, allowing smaller capsules to hold sufficient doses.

Understanding the relationship between volume and density ensures accurate dosing and optimal product performance.

Gelatin vs. Vegetarian Capsules: Size Differences

Capsule material also influences your decision.

Gelatin Capsules

Traditional and widely used
Smooth texture
Slightly more flexible for filling

Vegetarian Capsules (HPMC or Pullulan)

Plant-based
Suitable for vegetarians and allergy-sensitive consumers
Slight structural differences

While gelatin and vegetarian capsules follow similar Capsule Size Chart dimensions, slight variations in shell thickness may affect capacity minimally. For precision formulations, reviewing both charts is recommended.

Common Capsule Sizes and Their Uses

Here’s a general overview of frequently used sizes:

Size 000 – High-dose formulations
Size 00 – Very common in supplements
Size 0 – Versatile and widely used
Size 1 – Moderate doses
Size 2–4 – Smaller doses or easier swallowing
Size 5 – Smallest size; suitable for children or pets

Most human supplements commonly use sizes 0, 00, and 1 due to their balance between capacity and swallowability.

Ensuring Capsule Size Fits Your Equipment

Manufacturing compatibility is critical.

Not all encapsulation machines support every size. Many machines are optimized for sizes 0 and 00. If you plan to use sizes 3 or 4, confirm compatibility beforehand.

Using the wrong size can cause:

Production delays
Inaccurate fills
Equipment wear
Increased waste

The Capsule Size Chart acts as a bridge between formulation design and manufacturing efficiency.

How to Use a Capsule Size Chart Effectively

To get the most out of your Capsule Size Chart:

Determine required dosage.
Identify material density.
Check volume capacity.
Consider swallowing comfort.
Verify equipment compatibility.
Test multiple sizes if necessary.

Many formulators begin with size 0 and later switch to size 1 after testing swallowability and fill efficiency. The chart supports this optimization process.

Final Thoughts

A Capsule Size Chart is more than a simple reference—it is a strategic tool in capsule manufacturing. It ensures accurate dosing, improves user experience, maintains product quality, and enhances production efficiency.

Whether you manufacture pharmaceuticals, nutraceuticals, or dietary supplements, mastering the Capsule Size Chart will help you create safer, more effective, and market-ready products.

Types of Capsules By Structure

Types of Capsules By Function

Types of Capsules by Material

Frequently Asked Questions (FAQs)

1. What is a Capsule Size Chart?

A Capsule Size Chart is a reference table that shows capsule dimensions, volume capacity, weight capacity, and other technical specifications for sizes 000 to 5.

2. What is the largest capsule size available?

Size 000 is the largest commonly used capsule size.

3. What is the smallest capsule size?

Size 5 is the smallest standard capsule size.

4. How much powder can a size 00 capsule hold?

A size 00 capsule can typically hold around 735 mg, depending on the material’s density.

5. How does material density affect capsule selection?

Low-density materials require larger capsules, while high-density materials can fit into smaller capsules.

6. Are gelatin and vegetarian capsule sizes the same?

They generally follow the same size standards, but slight differences in shell thickness may affect capacity.

7. Which capsule size is most commonly used for supplements?

Sizes 0, 00, and 1 are the most commonly used for human supplements.

8. Why is capsule size important for manufacturing equipment?

Not all filling machines support every capsule size. Selecting the correct size prevents production issues.

9. How do I choose the right capsule size for children?

Smaller sizes such as 3, 4, or 5 are typically easier for children to swallow.

10. Can I change capsule size during formulation development?

Yes. Many manufacturers test different sizes to balance dosage accuracy, comfort, and production efficiency.

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Capsule Size Chart Guide: Sizes 000 to 5, Capacity, Weight & Selection Tips