How are softgel capsules manufactured?
Softgel capsules are usually manufactured using a rotary-die encapsulation process that forms two flexible shell ribbons, meters the liquid or semi-solid fill between them, and simultaneously shapes, fills, and seals each capsule. The capsules are then dried, inspected, tested, and packaged.
Answer
Softgel manufacturing is designed for formulations that can be filled as liquids, oils, suspensions, or suitable semi-solid systems.
A typical process includes:
1. Shell preparation
Gelatin or another suitable soft-capsule polymer system is blended with water, plasticizers, and any permitted colorants or other formulation components.
2. Fill preparation
The active ingredients and excipients are blended into a liquid, suspension, oil-based, or semi-solid fill formulation.
3. Ribbon formation
The shell mass is formed into two continuous ribbons.
4. Rotary-die encapsulation
The two ribbons pass between rotating dies while a precisely metered quantity of fill material is injected between them.
The dies simultaneously:
▸ form the capsule shape
▸ meter the fill
▸ seal the two shell halves
▸ cut the finished softgel from the surrounding ribbon
5. Drying
Freshly formed softgels contain relatively high moisture and are dried under controlled conditions until the shell reaches its required physical properties.
6. Inspection and sorting
Capsules are checked for leakage, deformation, improper seals, fill variation, or other defects.
7. Quality testing
Depending on the product, testing can include identity, assay, fill weight, disintegration or dissolution, microbiological quality, moisture, stability, and capsule integrity.
8. Packaging
Approved softgels are packaged into bottles, blisters, or other suitable containers designed to protect product stability.
AdvaCare Pharma manufactures a broad range of AdvaLife™ softgel supplements, including vitamins, minerals, oils, herbal formulations, and combination products.
Trust Our Expert Answers?