How IMA tackles the challenge of non-compressible nutraceutical powders

The nutraceutical market is increasingly driven by consumer demand for pure, natural products made from high-quality raw materials. As manufacturers respond to this preference, formulations without excipients are becoming more prominent. However, removing these functional ingredients can introduce significant processing challenges, particularly when working with powders that lack compressibility.

This article explores how IMA addresses the challenges associated with processing non-compressible nutraceutical powders using vacuum dosing technology and mechanical optimisations.

Conventional capsule filling technology relies on dosators and pistons to collect and compact powder into a slug before transferring it into the capsule. However, certain natural powders do not respond effectively to compression, resulting in incomplete or absent slug formation and potentially compromising dosing stability.

IMA's vacuum dosing technology offers an alternative approach. By creating a regulated vacuum within the dosing chamber, the system collects and retains powder without relying on compaction. Vacuum remains active throughout collection and turret rotation before being deactivated to release the powder into the capsule. For materials that respond partially to compression, combining light compaction with vacuum can further improve stability.

The article examines a case study involving 100% pure grape seed extract (Vitis vinifera), analysed at IMA's Active Competence Center. Laboratory testing assessed its density, flowability, moisture content and particle size distribution, identifying its non-compressible characteristics and tendency to adhere to metal surfaces.

Trials conducted on a ZANASI 40 capsule filling machine demonstrated the benefits of three key optimisations: dosators and pistons with suction, hard chrome-coated components to reduce powder adhesion, and a suction bowl to improve powder bed homogeneity and density.

Together, these solutions enabled more stable, repeatable dosing while reducing powder loss and weight variability. The case study demonstrates how IMA combines scientific powder analysis with tailored mechanical and process solutions to handle challenging natural formulations, supporting dosing accuracy, operational stability and continuous production without requiring excipients.

To explore the full case study and discover how IMA optimises capsule filling for non-compressible natural powders, click here to read the complete article.