Capsules, Tablets or Stick Packs? How to Choose a Private Label Supplement Format (Minimums, Testing and Label Rules)

Short answer: At PMG, capsules, tablets and stick packs run 5,000–10,000 units, while stock powders start as low as 1,000 units. Choose by dose and ingredients: capsules hold powder in a shell, tablets press it into a solid piece that can be coated, and stick packs hold one serving. All follow the same FDA quality rule, 21 CFR Part 111.

Definition — supplement format: the physical form a dietary supplement is sold in (capsule, tablet, softgel, powder, stick pack or gummy). The format sets your fill limits, packaging, testing, label wording and minimum order, so it is one of the first decisions in a private label project.

Key stats: supplement formats and buyers

• 57.6% of U.S. adults aged 20 and over used a dietary supplement in the past 30 days (2017–2018); women 63.8%, men 50.8%. Source: CDC/NCHS Data Brief No. 399.
• The most common types were multivitamin-mineral supplements, followed by vitamin D and omega-3. Source: CDC/NCHS Data Brief No. 399.
• 75% of Americans reported using dietary supplements in CRN's 2024 Consumer Survey (Ipsos, 3,194 U.S. adults). Source: Council for Responsible Nutrition, Oct 29, 2024.
• Magnesium use rose from 19% to 23% of supplement users between 2023 and 2024. Source: CRN 2024 Consumer Survey.
• FDA must receive a new dietary ingredient notification at least 75 days before a product containing it is marketed. Source: FDA.

Which supplement formats can a private label brand choose from?

PMG's partner facilities make capsules (hard gelatin and vegetarian), softgels, tablets (coated and uncoated), gummies, powders (bulk and stick packs), liquids and shots, and effervescent tablets. This guide compares three of them: capsules, tablets and stick packs. Gummies are a separate decision with their own minimums, covered in our low MOQ supplement guide.

How do capsules, tablets and stick packs compare?

Minimums: PMG's Nutraceuticals & Supplements page. Label terms: 21 CFR 101.36. Test times: USP general chapter <2040> (USP 35–NF 30 edition).

When are capsules the right choice?

Capsules are a common choice for powder blends because the powder goes into a ready-made shell instead of being pressed into a tablet. You choose the shell: traditional gelatin, or HPMC (hypromellose), a vegetarian shell made from plant-derived cellulose. A capsule maker's technical paper says HPMC capsules were developed because some consumers prefer products without animal ingredients, and reports that one HPMC capsule product showed three-fold lower average moisture content than gelatin capsules in a study, which can help with moisture-sensitive ingredients. Ask for stability data on your own formula rather than assuming the shell solves it.

Check the dose early. If one serving takes several capsules, that changes the label, the bottle size and the cost per serving.

When should you choose tablets instead?

Tablets press the blend into a solid piece. As PMG's supplements page notes, certain actives need coatings for stability or taste masking, and tablets can be made coated or uncoated. Ask your manufacturer whether your blend compresses cleanly before you commit. Where a USP monograph calls for a disintegration test, USP's chapter <2040> sets 30 minutes for uncoated tablets, so plan that testing into the timeline.

When do stick packs make the most sense?

Stick packs, often called sachets, are single-serve servings of powder. They can suit drink mixes and doses that would take several capsules per serving. The label serving is a "sachet", and each sachet holds one full serving. The practical questions are about the powder and the film: does it flow evenly into small sachets, and does it stay dry and stable on the shelf? Bulk powder in a tub is the lower-minimum version of the same product; at PMG, stock powders start as low as 1,000 units.

Do the FDA rules change by format?

No. Every format falls under the same supplement manufacturing rule, 21 CFR Part 111. Manufacturers must set specifications for the identity, purity, strength and composition of each finished batch, plus limits on contamination, and must verify that finished batches meet them (for every batch, or a subset chosen through a sound statistical sampling plan). That is what a certificate of analysis documents.

FDA does not approve dietary supplements before they are sold. The firm that makes or distributes the product is responsible for making sure it is not adulterated or misbranded. If your formula uses a new dietary ingredient (one not marketed in the U.S. before October 15, 1994), FDA must be notified at least 75 days before it goes on sale.

What does change is the label. The panel must be titled "Supplement Facts", and the serving size must use a term that fits the form, such as "tablets", "capsules" or "sachets". See our supplement label guide for the full list.

How do minimums and budget change by format?

Here are the minimums PMG publishes on its supplements page:

• Capsules, tablets and stick packs: 5,000–10,000 units
• Stock powders: as low as 1,000 units
• Select stock gummy formulas: as low as 500–1,000 units (60 count)
• Custom gummies: as low as 2,500 units (60 count)

Setup, testing and documentation are largely fixed for each run, so 10,000 units costs less per unit than 1,000. Private label programs on stock formulas usually launch in 60–90 days; custom formulations typically take 4–6 months. PMG quotes the format, fill and packaging together so the per-unit number reflects the real project. For a phase-by-phase budget, see how much it costs to manufacture supplements.

The 5-F Format Fit Check

Run your product through these five questions before you request quotes:

1. 1.Fill: How much powder is one serving, and how many capsules, tablets or sachets does that take?
2. 2.Feel: How will your customer take it: swallowed with water, mixed into a drink, or carried on the go?
3. 3.Fragility: Are any ingredients sensitive to moisture, heat or taste? Do they need a coating, an HPMC shell or a stronger sachet film?
4. 4.Funding: Does your budget cover the minimum for that format (5,000–10,000 units for capsules, tablets and stick packs at PMG)?
5. 5.Filing: What will the Supplement Facts panel say, does any ingredient need a new dietary ingredient notification, and what claims will you make?

Printable checklist: what to send a manufacturer for a format quote

Download the fillable checklist (PDF)

• ☐ Product type and target format (capsule, tablet, stick pack, bulk powder)
• ☐ Formula or ingredient list with the dose per serving
• ☐ Servings per bottle, box or carton
• ☐ Stock formula, modified stock or custom formula
• ☐ Quantity for the first run and expected reorders
• ☐ Target cost per unit and total budget
• ☐ Shell or coating needs (vegetarian/HPMC, coated tablet)
• ☐ Packaging (bottle, pouch, stick pack carton) and who supplies it
• ☐ Claims you plan to make (vegan, organic, structure-function)
• ☐ Sales channel (Amazon, retail, DTC, clinics)
• ☐ Launch deadline

Frequently asked questions

Glossary

• HPMC (hypromellose): a plant-derived cellulose material used for vegetarian capsule shells.
• Gelatin capsule: the traditional two-piece hard capsule shell.
• Softgel: a soft-shell capsule; USP <2040> checks these with a rupture test (15 minutes).
• Stick pack (sachet): a narrow single-serve sachet holding one serving of powder.
• Excipient: an inactive ingredient that helps a blend fill, flow or compress.
• Disintegration test: a lab test of whether tablets or capsules break apart within a set time.
• 21 CFR Part 111: FDA's current good manufacturing practice rule for dietary supplements.
• NDI (new dietary ingredient): an ingredient not marketed in the U.S. before October 15, 1994.

Ready to choose a format? Tell us the product, the dose and the quantity, and we'll tell you which format fits and what a first run takes.

See PMG's supplement manufacturing · start a project

About Product Management Group

PMG is a full-service private label manufacturing partner for skincare, nutraceuticals, supplements, personal care, and wellness brands. We handle everything from R&D and formulation through manufacturing, packaging, regulatory compliance, and fulfillment, working with FDA-registered, GMP-compliant partner facilities in Florida, North Carolina, Texas, Minnesota, and Arizona. We work with everyone from first-time founders to established retail brands, with minimums starting at 1,000 units.