Pelletization in the Nutraceutical Sector

Pelletization is emerging as one of the most innovative and rapidly growing technologies in the production of oral solid forms for the nutraceutical industry.

Already widely applied for several years in the pharmaceutical field, this technique allows the production of spherical pellets—uniform and precisely controlled in size—ensuring accurate and consistent dosing of active ingredients.

Its introduction into the nutraceutical sector, still in its early stages but strongly promoted and supported by Euronovis, brings with it all the distinctive advantages of pharma-grade technologies: enhanced therapeutic efficacy, greater safety, optimized production times, and the possibility to customize formulations according to specific clinical or commercial needs.

What Is Pelletization and Why Is It Used

Pelletization is a technological process through which powder blends are transformed into small, spherical solid units known as pellets.

These microparticles represent a multiple-unit oral dosage form, capable of providing high uniformity in the distribution of active ingredients, more controlled release profiles, and greater bioavailability compared to traditional tablets or capsules.

Thanks to their small size, pellets easily pass through the pylorus and reach the intestine, without being significantly affected by the digestive phases. This ensures optimal targeting of API, faster absorption times, and greater consistency in the biological effect.

Their versatility also makes it possible to combine multiple active ingredients within the same dose, offering innovative solutions for the personalization of dietary supplements and the development of advanced nutraceutical formulations.

Pellet Production Techniques

Two main approaches are used for pelletization in the pharmaceutical and nutraceutical fields:

1. Powder Layering (Build-Up on Inert Cores)
   In this technique, powdered active ingredients are progressively applied onto an inert core inside a coating pan or a fluid bed system. The controlled addition of binders and solvents allows the formation of uniform spherical particles, whose diameter and active ingredient content are defined according to the product’s specifications.

2. Extrusion/Spheronization
   In this process, the blend of active powders is extruded through a matrix, forming small cylindrical extrudates that are then spheronized to obtain perfectly spherical pellets.
   This technology provides excellent homogeneity, density, and flow properties, making it ideal for large-scale production. It also helps reduce process times and optimize raw material use.

Both techniques, when properly managed, allow precise control over pellet size, porosity, and active ingredient release rate, offering formulators complete control of the product’s pharmacokinetic profile. However, each method has its own specific advantages that must be carefully assessed depending on the project goals and product characteristics.

Drawing on its extensive pharmaceutical expertise and technical know-how, Euronovis guides its partners in selecting the most suitable, effective, and cost-efficient pelletization technology for each formulation.

The Advantages of Pellets in Nutraceuticals

In the nutraceutical field, the use of pellets opens up new possibilities for the formulation of complex dietary supplements.
Among the main advantages of pelletization are:

• Improved intestinal absorption thanks to faster gastric transit;

• Combination of multiple active ingredients with different release profiles within a single capsule or stick;

• Adaptability to multiple dosage forms, such as hard capsules, sticks, sachets, or orally dispersible formats;

• Greater physicochemical stability of active ingredients over time;

• Ease of swallowing and better patient compliance, especially for pediatric, senior, or sports populations;

• Functional design and aesthetic value, due to the regular, smooth, and color-customizable appearance of the pellets.

The pellet-based approach proves particularly advantageous for multivitamin and multimineral formulations, probiotics, supplements supporting gastrointestinal health, and sports nutrition products—sectors where dosage personalization and precision in release control are key elements for product success.

Innovation and Customization

The application of extrusion–spheronization or powder layering technologies requires advanced process engineering expertise and rigorous control of all production parameters.

Specialized companies such as Euronovis, with a strong background in coating, granulation, and pelletization processes, provide both scientific and operational know-how to support nutraceutical manufacturers throughout every stage — from formulation development to the finished product.

Each pelletization project is unique and fully customizable: from selecting the most suitable technology (powder layering or extrusion/spheronization), to defining pellet size, color, and release kinetics, and finally to the packaging stage.

The ultimate goal is to transfer pharmaceutical precision and quality into the nutraceutical sector, ensuring safety, efficacy, and market competitiveness through innovation and process excellence.