Softgel capsule manufacturer

A softgel is a solid dosage form consisting of a one-piece, hermetically sealed soft shell that encapsulates a liquid, semi-solid, or suspension fill. The shell is typically made from gelatin or vegetarian alternatives, along with water and a plasticizer.

Softgels are particularly well-suited for encapsulating oils and liquid-based ingredients, which may have better bioavailability or stability in this form. They are often easier to swallow than tablets and can effectively mask unpleasant tastes or odors. The sealed nature also protects sensitive ingredients from oxidation and degradation.

Ingredients that are liquid at room temperature, dissolved in an oil or liquid base, or stable suspensions/pastes are ideal for softgels. This commonly includes fatty acids (like Omega-3 fish oil), fat-soluble vitamins (A, D, E, K), CoQ10, plant oils, and certain herbal extracts.

Yes, for many fat-soluble or poorly soluble nutrients, encapsulating them in a lipid (oil) base within a softgel can enhance their absorption and bioavailability compared to powder or tablet forms.

Traditional softgel shells are made primarily from animal gelatin (often bovine or porcine), purified water, and a plasticizer like glycerin or sorbitol, which gives the shell its flexibility.

Many manufacturers now offer vegetarian and vegan softgel shells made from plant-based materials such as modified starches, carrageenan derived from seaweed, or HPMC (Hydroxypropyl Methylcellulose).

The primary difference is the source material (animal vs. plant). Vegetarian options cater to dietary restrictions. There can also be subtle differences in dissolution properties, moisture content, and compatibility with certain fill formulations, though modern vegetarian softgels are designed to perform comparably to gelatin.

Yes, softgels are specifically designed for these types of fills. Manufacturers are equipped to handle a wide range of viscosities and formulations, including solutions, suspensions, and pastes.

Materials that are highly aqueous (water-based) or have very low pH can be problematic as they can degrade the softgel shell over time. Dry powders are generally not encapsulated in softgels; hard capsules are more suitable for powders.

The sealed softgel shell is very effective at masking unpleasant odors and tastes. This is one of the key advantages of this dosage form, particularly for ingredients like fish oil or garlic.

Softgels come in many shapes, with Oval, Oblong, and Round being the most common. Other shapes include Tube, Suppository, and various novelty shapes (like fish). Sizes are designated by their approximate fill volume.

Softgel size is typically measured by the approximate volume of the fill material, commonly expressed in Minims or Cubic Centimeters (CC or mL). (Note: 1 CC is approximately 16.23 Minims).

Yes, manufacturers often offer customization options for color (using approved colorants), opacity, and printing (with food-grade ink). Custom shapes or specific non-standard sizes may be possible depending on the manufacturer's tooling capabilities, but usually involve higher MOQs.

Softgels are typically made using the rotary die encapsulation process. This involves simultaneously creating two ribbons of gel shell material, accurately injecting the liquid or semi-solid fill between them, and then cutting and sealing the softgels in one continuous operation. The softgels then go through a drying process.

Precise metering pumps are used during encapsulation to ensure the correct volume of fill material is injected into each softgel. In-process checks, including monitoring fill volume and weight variation, are performed frequently during the production run.

Quality control includes testing raw materials, in-process checks (like shell thickness, fill volume, seal integrity), and testing of the finished product. Finished softgels are visually inspected, and tested for parameters like fill weight/volume, disintegration/dissolution, and microbial limits.

Testing methods include visual inspection, physical tests to check the strength of the seam, and sometimes placing softgels under vacuum or pressure in a liquid medium to observe for leaks.

Finished product testing typically includes assay testing to confirm the potency (amount of active ingredient), purity testing for contaminants (like heavy metals or residual solvents), and microbial testing to ensure safety. Stability testing is also performed to determine the shelf life.

Yes, enteric coating can be applied to softgels. This coating prevents the softgel from dissolving in the acidic stomach, allowing it to pass into the small intestine before releasing its contents. Benefits include protecting ingredients from stomach acid, preventing stomach irritation, and reducing issues like "fish burps."

Yes, some manufacturers produce chewable softgels with modified shells and often flavored fills. They are a good option for consumers who have difficulty swallowing pills, such as children or the elderly, and provide a more pleasant consumption experience.

Yes, twist-off softgels are a type designed with a tab that can be twisted or snipped off to dispense the liquid fill. They are useful for precise dosing of liquids, particularly for infants, pets, or for products intended for topical application.