ABJ alive–Syntegon: the partnership accelerating the nutraceutical capsule market

Global demand for nutraceutical capsules continues to grow, driven by greater health awareness, the emergence of new ingredients, and the expansion of e-commerce. In this fast-moving landscape, manufacturers and CDMOs must handle increasingly complex formulations, ensure rapid time-to-market, and maintain high quality standards. It is within this context that the collaboration between ABJ alive and Syntegon takes shape—launched in 2018 and now evolved into a true model of technological co-creation.

ABJ alive, part of the 1Q Health Group and specialized in contract manufacturing of nutraceutical capsules, works with a wide range of ingredients—from probiotics to vitamins, from plant extracts to enzymes—often characterized by physical and biological properties that are difficult to handle. The need to switch quickly between formulations while maintaining process consistency and on-time delivery has made the adoption of reliable and scalable technologies a strategic priority.

The answer came with Syntegon’s GKF Capsylon series, designed for medium- to high-volume production in the nutrition and health sector. Following an initial trial, ABJ alive progressively expanded its machine fleet to the current six high-performance capsule filling machines installed at its Creussen facility. The results are significant: an overall 20% reduction in downtime and up to a 50% increase in efficiency when handling complex ingredients such as magnesium oxide.

A distinctive feature of Syntegon’s technology is the patented slide-gate system, which enables gentle dosing of raw materials, reduces product loss, limits the impact of powders on the machine, and allows pellets to be processed on the same dosing station. Ease of use, fast cleaning, and a favorable cost-performance ratio complete the picture.

As emphasized by Plant Manager Florian Geppert, the collaboration goes beyond equipment supply: “Syntegon supports ABJ alive as a long-term partner, contributing to process optimization and the management of increasingly complex formulations. This support translates into greater scalability and operational robustness, while ABJ alive retains full technological control”.

With 40% growth in 2025 and a stated goal of doubling capsule production, ABJ alive is looking ahead with a clear strategy: to continue investing in Syntegon technologies in order to support expansion and meet the challenges of an increasingly competitive market.