Propolis Capsule Manufacturer for Global Supplement Brands

We process propolis in two main forms: ethanol-extracted resin and water-extracted powder. Ethanol extraction yields a higher flavonoid content, typically 12-20% total flavonoids, while water extraction suits alcohol-free labelling. After extraction, the material is dried to a powder or paste and blended with carriers such as maltodextrin or silicon dioxide for flowability. Our encapsulation lines run two-piece gelatin or HPMC capsules at speeds up to 120,000 units per shift. Fill weights range from 200 mg to 800 mg of propolis extract per capsule, with fill weight variation held within ±5%.

For brands that need a propolis capsule manufacturer with flexible run sizes, we offer pilot batches from 1,000 units. This lets you test market response before committing to a 1,000-unit retail order. We can also produce blended capsules combining propolis with vitamin C, zinc, elderberry or echinacea. Capsule sizes include 0, 00 and 000, with optional enteric coating for delayed release. Tooling changes for custom capsule colours or print bands add 3-5 working days to the sample timeline.

Propolis is sticky and hygroscopic. That makes formulation a balance between active load and capsule stability. We typically recommend 200-400 mg of propolis extract per capsule, combined with 50-150 mg of a flow agent such as microcrystalline cellulose or silicon dioxide. If you need a standardised flavonoid claim, we can blend propolis with a defined extract ratio, for example 2:1 or 5:1. For vegan positioning, we use HPMC capsules and plant-derived carriers. For halal certification, we source gelatin capsules from certified suppliers and provide documentation for each lot.

Moisture content matters. Propolis powder above 5% moisture can soften gelatin capsules and cause clumping. We dry incoming extract to 2-3% moisture and run encapsulation in a controlled humidity room at 45-55% relative humidity. If your formula includes oil-based propolis, we can fill it into liquid capsules or convert it to a powder via spray drying. Every formulation is tested for disintegration time, which typically falls between 10 and 20 minutes for standard two-piece capsules.

Every propolis batch is tested for identity, heavy metals, microbial limits and residual solvents. For ethanol-extracted material, we check residual ethanol against EU and USP limits. We also screen for pesticides and antibiotics, which are common contaminants in raw propolis. Our facility is GMP-certified, ISO 22000 and HACCP compliant. We hold halal certifications and can source propolis on request. Each shipment includes a certificate of analysis, MSDS and, where needed, a free-sale certificate for Middle East markets.

Export documentation is prepared in-house. We handle commercial invoices, packing lists, certificates of origin and health certificates. For US-bound orders, we provide FDA-registered facility documentation. For EU orders, we supply documentation for novel food and supplement notification where applicable. Lead times for mass production are 20-35 working days after sample approval. Air freight to the US or EU typically takes 5-10 days; sea freight takes 25-40 days. We ship from Shenzhen and Hong Kong ports.

Every propolis capsule batch is tested at three stages: incoming raw propolis, the dried extract before blending, and the finished encapsulated product. Identity testing uses TLC and HPLC fingerprinting against a reference propolis sample to confirm the presence of marker flavonoids such as galangin and pinocembrin. Potency is quantified as total flavonoid content, typically expressed as quercetin equivalents, with a specification range agreed per SKU. Microbial testing covers total aerobic count, yeast and mould, E. coli, Salmonella and Staphylococcus aureus. Heavy metals (lead, arsenic, cadmium, mercury) are tested on every lot against EU and US pharmacopoeial limits. Disintegration testing follows USP <701> or Ph. Eur. 2.9.1, with a typical requirement of complete disintegration within 30 minutes for hard capsules.

The certificate of analysis (COA) issued with each batch lists the product name, lot number, manufacturing date, expiry date, capsule fill weight, and the specification and result for every test performed. It also names the testing laboratory and the release decision. Where a customer requires it, we include the chromatographic fingerprint as an appendix. Retention samples of both the finished capsules and the bulk extract are held for the shelf life plus six months, stored under the same conditions as the commercial stock. This allows re-testing if a market complaint arises or if a customer audits the batch history.

Stability follows a standard protocol: accelerated conditions at 40°C and 75% relative humidity for six months, and real-time conditions at 25°C and 60% relative humidity for the declared shelf life, typically 24 months. Capsules are tested at 0, 3, 6, 9, 12, 18 and 24 months for appearance, fill weight, disintegration, microbial limits and flavonoid content. We provide the stability summary report to support the customer's own shelf-life declaration. If a customer needs a shorter or longer shelf life, the protocol is adjusted at the quotation stage so that the testing schedule matches the intended market.

Batch documentation is compiled into a batch record that includes the raw material COAs, in-process checks (blend uniformity, capsule weight variation, lock length), finished-product test results, and the packaging and labelling records. This file is retained for five years and is available for customer review during audits. Where the customer's market requires it, we arrange third-party testing at an accredited external laboratory and include those reports in the release package. We do not release a batch until all specification results are within limits and the QA sign-off is complete.

Propolis capsules can be packed in high-density polyethylene (HDPE) bottles with induction seals and child-resistant or standard caps, in blister packs using PVC/PVDC or aluminium cold-form foil, in stick packs, or in single-serve sachets. Bottle sizes range from 30 to 180 capsules, with typical retail counts of 60 or 90. Blister configurations are 10 or 12 capsules per card. Stick packs and sachets are filled with a counted number of capsules or with a powder blend if the customer prefers a drink mix format. We can supply unlabelled bottles for the customer's own labelling line, or apply labels in-house.

For the US market, the label must include the statement of identity, net quantity of contents, supplement facts panel with serving size and percent daily value where established, ingredient list in descending order of predominance, and the name and place of business of the manufacturer, packer or distributor. Allergen and advisory statements are included where applicable. For the EU, the label follows Regulation (EU) No 1169/2011 and the Food Supplements Directive 2002/46/EC, with nutrition declaration and recommended daily portion. We prepare print-ready artwork for customer approval and do not print until written sign-off is received.

Lot and expiry coding is applied by inkjet or laser on the bottle base, label or carton, in the format agreed with the customer. We can also apply a best-before date and a retest date if required. Cartons are specified with dimensions, board grade and printing, and pallets are configured to the customer's preferred footprint, typically 1200 x 800 mm or 1200 x 1000 mm, with stretch wrapping and edge protection. For Amazon FNSKU labelling, we apply the FNSKU barcode label over the existing barcode or on a clear area of the carton, and we can poly-bag and label units to Amazon's preparation requirements.

Retail readiness checks include barcode verification (EAN-13 or UPC-A) against the customer's GS1 data, label text proofreading against the approved artwork, and a packaging line check for seal integrity and cap torque. We do not hold any retail certifications in our own name; any organic, halal or vegan claim on the label must be supported by certificates held by the customer or by the ingredient supplier, and we will only print such claims after receiving valid certificate copies. This avoids unsubstantiated claims on the finished product.

The sample process starts with a technical review of the customer's specification, including extract type, fill weight, capsule size and packaging format. We then produce a sample batch of 100 to 500 capsules for customer evaluation. Sample lead time is 7 to 10 working days from receipt of the signed specification and, where a custom label is required, the approved artwork. Sample cost is quoted per project and is typically credited against the first mass-production order. Samples are sent by courier with a commercial invoice and packing list.

Mass production begins after sample approval and receipt of the purchase order and deposit. The production window is 20 to 35 working days for standard capsule counts and packaging, and up to 45 working days where custom packaging components or third-party testing are required. We provide a production schedule at order confirmation and update it weekly. Quality release and packing add 3 to 5 working days before dispatch. We do not guarantee delivery dates that depend on customer-supplied components, but we will flag any risk as soon as it is identified.

Shipping is arranged by air or sea depending on volume and urgency. Air freight is typically used for orders under 500 kg and delivers in 5 to 10 days to major hubs. Sea freight is used for larger orders and takes 25 to 40 days depending on the destination port. We ship under EXW, FOB or DDP terms; DDP is available for selected markets where we have a customs broker relationship. The commercial invoice, packing list, bill of lading or air waybill, certificate of origin and insurance certificate (where applicable) are provided with each shipment.

The document pack includes the certificate of analysis for each batch, a material safety data sheet (MSDS) for the finished capsules, and a free-sale certificate issued by the relevant authority where the destination market requires it. For markets requiring phytosanitary certification for bee-derived products, we arrange inspection and issue the certificate through the local plant health authority. We also provide a declaration of origin and, where requested, a statement of no genetically modified material. Customers should confirm the exact document set for their market at the quotation stage so that any additional testing or certification can be scheduled into the lead time.