Most capsule projects spend months on the formula, weeks on the shell, then approve the blister in a ten minute meeting. In single dose skincare that order is backwards. The outer pack is the first thing a buyer touches in store, the only barrier between an oxygen sensitive softgel and a humid warehouse, and increasingly the first question a retail buyer asks about sustainability.
CapsulesBiotech fills facial serum oils, eye serums, hair oils, body lotions, face creams and masks into softgels, with shells in 100% plant based material or food grade gelatin. Filling is only half of the project. How the capsule is presented, protected and shipped decides whether the format feels premium or looks like a pharmacy commodity.
Three decisions shape the rest: blister material, carton structure, and the recyclability story you can actually defend with paperwork.
Start With the Blister, Not the BoxPVC with a PVDC coating remains the default because it runs fast and holds a strong moisture barrier. PET and PE mono material blisters are requested more often now, since they fit recycling streams better, but they need tighter forming temperatures and a machine trial before you commit. Cold form aluminium is reserved for the most sensitive fills. Cavity depth should be cut for the capsule you actually sell: a 0.2ml eye capsule and a 1ml body capsule cannot share a stock tool without rattling or denting.
- Cavity depth sized to the capsule, not to the nearest stock tool
- Foil gauge matched to barrier needs rather than habit
- Perforation that opens cleanly without tearing the lid foil
The carton is where the brand lives: board weight, finish, colour, copy. Specify FSC certified board, a single material construction, and a water based varnish instead of plastic lamination if you want an honest recycling story. 350gsm reads as premium in the hand, while 300gsm travels lighter and costs less. Ask for the dieline early, then confirm it holds the leaflet, batch code, and mandatory lines for each market.
Moisture, Light, HeatSoftgels are anhydrous, yet gelatin shells still pick up moisture from humid air, and plant shells, while more forgiving, are not immune. A well specified blister with a good foil can often remove the need for a desiccant sachet. Before the carton goes to print, run drop, vibration, and a 40C / 75% RH chamber check on the finished pack, not on bare capsules.
Recyclability: Claim Only What You Can ProveBuyers now ask for PVC free, mono material, or paper based formats. Each claim needs a paper trail: material certificates, a design for recycling assessment, and a disposal instruction that matches the local stream. A blister with aluminium foil laminated to plastic is rarely recyclable in household collection, so state the materials plainly instead of printing a broad green claim that a compliance team will challenge.
- Target markets plus any packaging registration you already hold
- Fill count per blister and per carton
- Artwork stage and dieline ownership
- Expected annual volume per SKU
Sequencing matters as much as specification. Tooling usually takes two to three weeks, printed proofs about one, and a first article inspection adds a few days before mass production. Brands that lock packaging alongside the formula avoid the common delay where filled capsules sit in storage waiting for a carton.
If you are planning a capsule line, send us your target market, price positioning, and preferred capsule size. Our team will come back with formula direction, fill volume options, packaging formats, and a production schedule that fits your launch window.