Solid dosage forms, such as tablets and capsules, offer unique advantages compared to other delivery forms like gummies, candies, liquids, powders, and oral strips. These forms continue to grow in popularity; in fact, the global market for oral solid dosage forms, including pharmaceuticals, was valued at $524.6 billion in 2021 and is projected to exceed $1.03 trillion by 2032, with a compounded annual growth rate (CAGR) of 6.4%.
This article will explore the various solid dosage formulation options and help you determine which might be the best fit for your dietary supplements.
Exploring Different Solid Dosage Forms
There are several solid dosage form examples. These include capsules, tablets, chewable tablets, effervescent tablets, quick melts and lozenges. Below is a discussion of each of these solid dosage forms.
Capsules
There are several advantages associated with capsules. They offer stability, ease of handling, accurate dosing, and lack of preservation requirements. In addition, with the use of microencapsulated ingredients, encapsulated products can be produced to offer controlled or delayed release options, thereby improving bioavailability and dosage convenience.
Capsules also do a great job at masking bitter or otherwise undesirable tastes associated with certain ingredients. Furthermore, their smooth texture makes them relatively easy to swallow.
With two-piece hardshell capsules, the smaller half of the capsule is filled and secured into the larger half. Two-piece hardshell capsules are particularly suitable for powdered nutraceuticals.
The pros and cons of two-piece hardshell capsules include:
- Pro – Users won’t taste bitter or unpleasant ingredients.
- Pro – Available in gelatin, vegetarian and organic forms.
- Pro – Delayed release nutraceutical beadlets can be included within the capsules.
- Pro – Enteric coating is available to protect against breakdown in the stomach.
- Pro – Precise dosage and consistent formulation.
- Pro – Binders are not required.
- Pro – Long shelf life and stability.
- Pro – Suitable for a wide range of ingredients.
- Con – Generally contains a lower dose of nutraceuticals than tablets.
- Con – Very large capsules may still be difficult to swallow.
Softgels
Softgels are typically filled with oils or active ingredients that have been suspended or dissolved in oils.
The pros and cons of softgels include:
- Pro – Available in both gelatin and vegetarian forms.
- Pro – Precise dosage and consistent formulation.
- Con – Generally contains a lower dose of nutraceuticals than tablets.
- Con – May have a mild taste from the softgel casing.
- Con – Often contains animal ingredients (e.g., gelatin).
Tablets
The popularity of tablets as solid dosage forms is second only to capsules. Tablets are made by compressing powders or granules of nutraceuticals and excipients into a solid form. Tablets can come in many different shapes, sizes, and weights, depending on their intended use, and undergo the additional manufacturing step of coating to make the tablet smooth and easier to swallow. Coatings may also include a color element.
Another advantage of tablets is they can provide higher doses of nutraceuticals than a capsule. Furthermore, tablets may be scored in the middle, making it easy to break in half. This makes the tablet smaller, so it is easier to swallow. As with capsules, tablets can be made to provide controlled and extended-release functionalities. Tablets can also be produced in chewable, effervescent, quick melt and lozenge form, as discussed below.
The pros and cons of tablets include:
- Pro – Users won’t taste bitter or unpleasant ingredients.
- Pro – Can be manufactured to meet vegan requirements.
- Pro – Precise dosage and consistent formulation.
- Pro – Customizable tablet shapes and color coatings.
- Pro – Long shelf life and stability.
- Pro – Suitable for a wide range of ingredients.
- Pro – Certain tablets may be split or crushed for easier swallowing.
- Pro – Generally contains a higher dose of nutraceuticals compared to capsules.
- Con – Bitter or unpleasant tastes may be more noticeable.
Chewable Tablets
Chewable tablets that are specially formulated to deliver a payload of vitamins, minerals and/or other nutraceuticals with highly palatable flavor options, sweetening options, a desirable mouth feel, and good stability. Chewable tablets may be produced in different sizes and shapes to accommodate a wide range of nutraceutical doses and a pleasing esthetic appearance. The scientific journal, Systemic Reviews in Pharmacy, has this to say chewable tablets:
“Chewable tablets are versatile dosage forms that combine the manufacturing and stability advantages of solid dosage products while offering beneficial organoleptic [flavor/taste] and administration benefits.”1Antil A, Kahiy M, Tomar D. An Overview on Efficacy of Chewable Tablets in Improving Oral Drug Delivery. Systemic Reviews in Pharmacy. 2023; 14(9): 571-7.
As with any oral delivery form that the user will taste, some nutraceuticals with bitter or otherwise undesirable taste characteristics may not always work well in chewable tablets—although the use of bitter masking agents and specific flavors may help compensate in these instances.
The pros and cons of chewable tablets include:
- Pro – Suitable for individuals who have difficulty swallowing pills.
- Pro – Can be manufactured to meet vegan requirements.
- Pro – Added flavoring may make taking the supplement more appealing.
- Pro – Precise dosage and consistent formulation.
- Con – May contain artificial colors, flavors, and/or sweeteners (although natural options are available).
- Con – Bitter or unpleasant tastes may be more noticeable.
Effervescent Tablets
Effervescent tablets are designed to release carbon dioxide upon contact with water, giving them their characteristic fizzing effect and promoting their disintegration. Within a couple of minutes, the tablets completely dissolve and the nutraceuticals provided become available in solution. Microencapsulated and controlled-release effervescent tablets offer the potential for faster absorption of the active ingredients. The opportunity to improve taste, gentle action on the stomach, and more consumer appeal have made effervescent tablets a popular choice. An advantage to effervescent tablets is that they can contain substantial amounts of active ingredients due to their drinkable form.
As with chewable tablets, some nutraceuticals with bitter or otherwise undesirable taste characteristics may not always work well in effervescent tablets. Likewise, ingredients with a higher moisture content or that may easily absorb moisture may not work well in effervescent tablets since the moisture may deactivate the fizz.
Fast-Melts & Lozenges
Fast-melts and lozenges are orally disintegrating tablets. Fast-melt tablets dissolve quickly in the mouth (generally in one minute or less) without the need for water. Likewise, lozenges are tablets that are also designed to dissolve in the mouth (generally within a few minutes). As with chewables, this makes fast-melts and lozenges easy to swallow and a great alternative delivery form for people with difficulty swallowing pills or with pill fatigue.
Both fast-melts and lozenges don’t require much sugar and offer a pleasant mouth feel. Still another advantage is that a great variety of flavors can be used with fast-melts and lozenges (the same can be said for chewables).
Another advantage of fast-melts and lozenges is bioavailability. Some research has demonstrated enhanced bioavailability with orally disintegrating tablets (ODT). One study found that when used in ODT form, vitamin B12 had good bioavailability, raising serum levels by as much as four-fold2Delpre G. Sublingual therapy for cobalamin deficiency as an alternative to oral and parenteral cobalamin Supplementation. Lancet. 1999;354:740-750.. A similar human study3Sharabi A, Cohen E, Sulkes J, Garty M. Replacement therapy for vitamin B12 deficiency: comparison between the sublingual and oral route. Br J Clin Pharmacol. 2003 Dec;56(6):635-8. also found that the ODT delivery form increased serum concentrations by about three-fold. Good results were also seen with an ODT melatonin.4SaberMoghaddam M, Sheybani S, Bakhtiari E, Shakiba M. The Effect of Preoperative Sublingual Melatonin on Postoperative Pain Severity in Patients Undergoing Colorectal Surgery: A Triple-Blinded Randomized Trial. Med J Islam Repub Iran. 2022 Aug 10;36:90. Other ODT nutraceuticals may also have good bioavailability.
When you want the nutraceutical payload to dissolve as quickly as possible, fast-melts are the best option. When you want the payload to remain in the mouth for a slightly longer period—such as in the case of zinc or certain oral probiotics—lozenges are the way to go.
As with chewable and effervescent tablets, some nutraceuticals with bitter or otherwise undesirable taste characteristics may not always work well with fast-melts or lozenges.
Trends in Solid Dosage Manufacturing
Naturally there are consumer considerations for delivery form preference52020 CRN Consumer Survey on Dietary supplements.:
Capsules and tablets are both popular options in the supplement industry, although market trends for each preference differ according to the generation6Nutrition Business Journal, Delivery Format Special Report (US consumers who frequently take supplements), 2023:
It should be noted that chewable tablets are also popular. Consider that the global size of the chewable vitamins and supplements market was $4.7 billion in 2021 and is projected to reach $6.3 billion by 2027 with a CAGR of 5.01% during the forecast period7Chewable vitamins and supplements market report overview. Business Research Insights. Retrieved July 30, 2024 from https://www.businessresearchinsights.com/market-reports/chewable-vitamins-and-supplements-market-109227..
While specific data on fast-melts and lozenges as dietary supplement oral solid dosage forms is currently lacking, increasing customer demand for these options suggests they are also growing in popularity.
How to Choose the Best Solid Dose Form for Your Supplement Formulation
When choosing the best solid dose manufacturing option for your dietary supplement, there are several pieces of criteria to consider:
- Dose range of active ingredients – If the active ingredients in your formulation require a relatively high dosage level, then it is best to utilize capsules or tablets. Tablets will accommodate the highest dose for the lowest number of pills, with capsules following a close second.
- Bioavailability – While all the oral solid dosage forms explained in this article have good bioavailability, fast-melts and lozenges offer quicker disintegration with an extra degree of bioavailability for nutraceuticals like vitamin B12 and melatonin. Likewise, microencapsulated ingredients can be included in encapsulated and effervescent products to offer controlled or delayed release options, thereby improving bioavailability and dosage convenience.
- Stability/shelf life – If manufactured correctly, all of the oral solid dosage forms have good stability/shelf life. However, in those situations when you wish to maximize stability/shelf life, capsules are best, followed closely by tablets.
- Taste and texture – Chewables, melts, and lozenges all impact the taste experience for users. If the nutraceuticals have bitter or otherwise undesirable flavors, masking these can be challenging. In such cases, capsules often present a simpler solution. Among these options, melts typically offer the most appealing texture and mouthfeel.
- Cost-Effectiveness – Capsules, followed by tablets, offer the greatest cost-effectiveness.
- Consumer preference – Consumer preference for oral solid dosage form depends a great deal on the target population. Boomers tend to prefer capsules and tablets, while younger generations are more likely to prefer alternative delivery forms like melts.
- Production complexity – Oral solid dosage forms that require flavors and sweeteners, such as chewables, melts and lozenges, involve greater production complexity. Softgel production is also more complex. Capsules and tablets have the least production complexity.
Following is a decision-making matrix comparing solid dosage manufacturing forms across key criteria:
| Format | Tablet | Chewable | Capsule | Lozenge | Quick Melts | Effervescent |
| Target Release Profile | Immediate, Sustained, Controlled | Immediate | Immediate | Slow, Sustained | Immediate | Immediate, Sustained, Controlled |
| Dose Range | Wide | Moderate | Wide | Limited | Moderate | Sustained, Controlled |
| Taste and Odor Concerns | Low-moderate | High | Low | High | High | High |
| Stability | Moderate-high | Moderate | High | Moderate | Moderate | Moderate |
| Production Complexity | Low-moderate | Moderate | Low | Moderate | High | High |
| Cost Considerations | Moderate | Moderate | Moderate | Moderate | High | High |
Conclusion
Solid dosage forms, like capsules, tablets, chewables, effervescent tablets, quick melts, and lozenges, are becoming more popular because they offer specific benefits. Each of these oral solid dosage forms has its own advantages, so it’s important to weigh these differences when choosing the best option for your supplement.
A good contract development and manufacturing organization (CDMO) can help you choose the best solid dosage forms for your products. Vitaquest is a CDMO that has provided nutraceutical businesses with best-in-class supplement formulation design, contract manufacturing, packaging, particle and powder engineering using fluid bed, oscillation, and roll compaction technologies, and fulfillment services for over 45 years. Whether you’re a newcomer to the industry or aiming to diversify your product range, Vitaquest possesses the expertise, cutting-edge facilities, and solutions needed to swiftly and effectively turn your solid dosage formulation concept into reality, with a focus on the right oral solid dosage from for your products.
Vitaquest also has expertise in domestic and international regulatory standards. In fact, we are GMP certified by NSF, providing assurance to brand owners and consumers alike about compliance with industry regulations and standards. In addition, Vitaquest can offer Kosher, Halal, and certified organic products, and FSSC 22000 certification for food safety.
Are you ready to move forward with creating high-quality oral solid dosage forms for your brand? If so, call 800-526-9095 to speak with one of our knowledgeable sales executives or request a competitive nutraceutical manufacturing price quote if you’ve already finalized your project requirements!
