Cap-in-Cap capsules for dietary supplements

In the cap-in-cap system, a small capsule is integrated into a larger capsule. This allows multiple ingredients to be released separately, at different times, or in combination.

This technology is perfectly suited for:

• Powder + oil combinations
• Powder + Powder (e.g., sensitive active ingredient separated from the rest)
• Oil + spheres
• Delay-release formulations
• up to three components in one capsule

Cap-in-Cap offers you maximum flexibility and opens up completely new product ideas in the NEM market.

The technology enables combinations that would otherwise not be stable, technically feasible, or acceptable in terms of taste.

Possible combinations:

• Inner capsule containing oil, e.g., astaxanthin oil mixture
• Outer capsule containing powder or active ingredient matrix
• Spheres or pellets for delayed release
• Multi-component formulas that must remain separate from each other
• lipophilic + hydrophilic active ingredients in one capsule
• Actively shielded active ingredients (e.g., strong-smelling or sensitive raw materials)

This makes it possible to develop products that would be impossible in traditional capsules.

Cap-in-cap is ideally suited for delayed release:

• Delayed dissolution of the inner capsule
• DR/Delayed-Release effects through special HPMC capsules
• additional protection through coating processes
• Combination of different release profiles in a single capsule

This allows the creation of functional formulas such as:

• morning/evening release
• two-stage drug absorption
• Protection of sensitive ingredients
• targeted gastrointestinal release

The result:
A technology that is normally only used by large pharmaceutical manufacturers.

The process consists of several coordinated steps:

1. Production of the inner capsule

Filling with powder, oil or spheres, depending on the formulation.

2. Drying, stabilisation & quality control

Ensuring a tight seal and optimal consistency.

3. Coating (optional)

Delays the release of active ingredients or protects the inner components.

4. Integration into the outer capsule

The inner capsule is placed inside a second hard capsule and combined with further components.

5. Final inspection & sorting

Every batch is checked, sorted and prepared for the subsequent packaging process.

This multi-stage process creates high-quality, innovative premium capsules that stand out clearly from conventional capsules.

Cap-in-Cap systems are particularly suitable for:

• Premium and high-end products
• Functional complex formulations
• High-priced niche products
• Brands seeking a truly unique selling proposition
• Products with several types of active ingredients (powder, oil, pellets)
• Export markets that demand innovation

This technology is available from very few manufacturers in Europe – a strong USP for your brand.