Autopack: A guide to nutraceutical packaging equipment and pack formats

The global nutraceuticals market is forecast to grow significantly over the coming decade, creating opportunities for established manufacturers and emerging brands. Currently valued at around $500bn globally, that figure could hit over $1trillion by 2034. In the UK, the nutraceuticals market was valued at $31.2 billion in 2025 and forecast to reach $68.6 billion by 2035.

This growth is fuelled by an explosion in consumers taking a more proactive approach to nutrition, fitness and healthy ageing, while manufacturers continue to introduce products targeting increasingly specific lifestyles and requirements. E-commerce has also given emerging brands a relatively direct route to consumers, supporting more product launches and greater choice.

Nutraceuticals cover a broad range of tablets, capsules, gummies, powders and liquids. UK government guidance defines food supplements as concentrated sources of vitamins, minerals or other substances with a nutritional or physiological effect, sold in dose form. Common examples include vitamins and minerals, protein powders, creatine, fish oils, omega-3 products and botanical supplements.

So, this broad scope creates opportunities for manufacturers, and it demands a highly strategic approach to packaging. Different products require different dosing systems, protective properties and pack formats. The packaging equipment must deliver the necessary efficiency without compromising accuracy, cleanliness or flexibility. A well-specified line brings operations together to improve dosing accuracy, reduce manual handling and provide the flexibility needed to accommodate changing products and pack sizes.

What packaging formats are used for nutraceuticals?

Autopack works across rigid packaging machinery, flexible packaging machinery, weighing and inspection, enabling its engineers to consider the complete application rather than one isolated machine. This includes the product’s handling characteristics, pack format, required accuracy, batch sizes, changeovers and future production plans.

Rigid plastic or glass bottles remain a familiar format for tablets, capsules, soft gels and gummies. They provide protection during distribution, offer space for branding, regulatory guidance, food safety and product information, and can incorporate tamper-evident or child-resistant closures where required.

The packaging process may include bottle unscrambling, tablet or capsule counting, desiccant insertion, filling, capping, induction sealing, labelling and coding. Integrating these operations can reduce manual handling while improving consistency and throughput.

Jars and tubs are widely used for protein powders, meal-replacement products, collagen and other powdered formulations. Their wide openings make it easier for consumers to scoop and dispense the product. However, their size means efficient container handling, filling and closure application are essential if production is to remain cost-effective.

Flexible packaging is becoming increasingly prominent. Stand-up pouches can be used for protein powders, powdered vitamins, functional ingredients and refill products. They are lightweight and can provide a strong surface for branding, while resealable closures help protect the product after opening.

Stick packs and sachets offer another route to convenient, pre-measured portions. They are well suited to powders, granules, gels and liquids intended for on-the-go consumption. Individual doses can also support trial packs and variety boxes.

Liquid supplements, including oils, vitamin formulations and wellness shots, may be packaged in bottles, vials, sachets or stick packs. Each product requires a filling system suited to its viscosity, dose size and hygiene requirements.

Choosing the correct filling and dosing technology for nutraceuticals

There is no single packaging machine that suits every application. Equipment should be selected around the characteristics of the product and the pack.

Auger fillers are commonly used for powders because they can provide controlled, repeatable dosing. Products with inconsistent flow characteristics may require additional agitation, specialised hopper designs or dust-control measures.

Tablets, capsules and gummies can be handled using electronic counting systems, while liquids might require peristaltic, piston, flowmeter or net weight filling technology. Multihead weighers and volumetric dosing systems may be appropriate for granules or larger solid pieces.

Accuracy is particularly important. Overfilling creates avoidable product giveaway, which can become costly when packing high-value formulations. Underfilling can create quality and compliance problems.

Checkweighers, metal detectors, X-ray systems and vision inspection are critical for verifying pack quality and identifying contaminations, used in the middle or at the end of the production lines. Using the strength of the Autopack Group, relevant Autoweigh weighing and inspection systems help manufacturers address portion control, pack verification and product-flow requirements within one project and across rigid or flexible packaging lines.

Improving efficiency through nutraceutical packaging automation

Efficiency should be considered across the complete packaging line rather than at one individual machine.

A fast filler will not deliver the expected output if bottles, caps, labels or finished packs cannot move through the surrounding processes at the same rate. Lines should be balanced so that container handling, dosing, closing, inspection and end-of-line operations work together at a sustainable speed.

Automated feeding and handling can reduce repetitive manual tasks. Quick-change tooling and adjustable guides can also shorten changeovers between products and pack sizes. This is particularly valuable in nutraceutical manufacturing, where businesses may run a wide variety of stock-keeping units in relatively small batches.

End-of-line automation should not be overlooked. Cartoning, case packing, palletising and pallet wrapping can create bottlenecks if they remain heavily dependent on labour. Integrating these stages can improve product flow and free operators to focus on quality control and line management.

Building flexibility into the nutraceutical packaging line

The nutraceuticals market continues to evolve, so packaging machinery should not be specified solely around today’s product.

Manufacturers should consider whether the line might need to handle new bottle sizes, pouch formats, formulations or closure types. Modular equipment that can be upgraded, reconfigured or connected to additional machinery can provide a more secure long-term investment.

As an independent packaging line integrator, Autopack Group can select equipment from different manufacturers according to the requirements of the application. The aim is not to assemble a collection of standalone machines, but to create an integrated solution covering filling, closing, inspection and end-of-line packaging. Autopack’s current equipment portfolio includes powder filling, pouch and sachet machinery, liquid fillers, cappers, labellers, metal detectors, X-ray systems and checkweighers.

Planning a nutraceutical packaging project? Speak to Autopack about your product, target dose, pack format, batch sizes, required output and available production space. Our team can help you assess the filling, closing, weighing, inspection and end-of-line technologies needed for an integrated packaging solution.

This article was originally published by Autopack.