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Softgel Encapsulation 101: Everything You Need to Know

Major consumer pharmaceutical brands like Advil as well as countless others line pharmacy shelves with softgel products that people use every day. Thanks to early 20th century innovations that developed the encapsulation process, we now enjoy a pill form that is easier for many to swallow and benefit from. This alternative to traditional tablets and capsules remain just as popular today. 

The softgel and its encapsulation process both can trace their roots back to an inventor named Rober Pauli Scherer of Detroit. In 1930, the entrepreneur and chemical engineer developed the first softgels to offer the consumer an alternative to traditional solid medications. The end goal was simple: produce something that was both easier to swallow and to prevent tampering. The firm outer shell will leak and deflate if compromised, which can alert customers far easier than a standard tablet or capsule. 

Fast forward over 90 years, and surprisingly, little has changed when it comes to the softgel encapsulation process. Most of Scherer’s original manufacturing and design principles remain intact, although we now enjoy some modern conveniences not present in the early 20th century. For instance, many of today’s encapsulation machines grant the capability to produce larger batches of products at higher speeds and greater scale along with modern features like touchscreen control panels. 

Scherer’s initial vision led to one of the most impactful innovations in the pharmaceutical industry. In fact, we at CapPlus owe a great deal to his original inventions. Our commitment to constantly enhancing your ability to manufacture better pharmaceuticals at scale stem, in large part, from this idea that a person developed in Detroit almost an entire century ago. 

Today, pharmaceutical manufacturers must possess a softgel encapsulation machine in their equipment arsenal to remain viable in a highly competitive industry. If you do not already have one at your production facility, you are missing out on potential new business opportunities. 

Offering a full suite of machinery to your contract manufacturing clients or to your in-house production team will prove a worthwhile investment for your business. The best part? The softgel encapsulation process is rather straightforward when you use the right equipment. 

If you are considering adding softgel manufacturing to your operations or you simply want to learn more about the process, here is a comprehensive breakdown for you. 

Components of a Softgel Capsule 

At a glance, the softgel capsule is composed of two basic components: the liquid filling and the shell. 

The Shell

The shell of a softgel capsule is usually made of an animal gelatin-based compound that hardens during the production process to create a firmer exterior to protect and contain the liquid filling. The hardness of the external coating can vary based on the drying portion of the entire manufacturing cycle. 

While animal gelatins are the most common form of softgel coating, some pharmaceutical manufacturers opt for alternative materials to accommodate others with dietary restrictions. For example, one could use a vegetable-based gelatin or vegan tapioca starch to create a shell instead. 

It should be noted, however, that if one opts for a non-animal-based shell material, these alternatives could have different viscosities than animal gelatin. Vegetable gelatin is more viscous, for instance, and requires higher temperature settings during the manufacturing process to achieve a similar finished product. 

Liquid Filling

The liquid filling of a pharmaceutical softgel capsule usually consists of a combination of active medication and inactive carrier ingredients. During the process, the liquid is injected into the shell where it will remain until consumed by the user. 

The viscosity of the liquid filling can also vary depending on how much water is intentionally extracted from the mixture during the process. Softgels can also be filled with an oil mixture as well, such as a common over-the-counter Omega-3 capsule. 

The Process

The softgel encapsulation process involves the use of a single machine that can control each step from start to finish. They can vary in physical size, batch production capability, and how many capsules can be produced simultaneously. 

The Most Important First Step in the Process: Ensuring Humidity Control 

Because the softgel encapsulation process involves the handling of liquids and soft solids, maintaining proper humidity levels in the production environment is an essential step to assuring product quality. Too humid or too dry and the finished product will not match expectations. 

Ideally, an encapsulation workspace should maintain a temperature of 70 to 75 degrees Fahrenheit along with a 30-35% relative humidity. The drying tunnels connected to or within the machines can be less humid than the external workspace. 

Creating and Filling  the Shell 

The softgel shell begins as two ribbons of a animal-gelatin, vegetable-gelatin, or tapioca starch being spun on a pair of rotating dies. Depending on the shell material you are working with, you will have to adjust the temperature to compensate for its viscosity.  

When ready to form the shell, the dies cut the ribbons and bring them together to form a seal. After this, the liquid filling is injected. The newly joined and filled halves are expanded into a three-dimensional shape as they dry. 

Closing the Seal and Drying

After the shell has formed and expanded, the product is then heated to complete the seal. After this, it is deposited into the die pockets that will form its final shape and dry. 

Here is where the manufacturer can decide to remove excess moisture from the finished product. The amount of moisture removed will directly determine the firmness of the capsule. If more moisture is extracted, then the capsule will have a firmer texture. If less, then the capsule will have a softer, more “squishy” consistency. 

Cooling

Once the softgel has dried, the cooling process begins. The three most common methods for cooling the finished capsule product include, but are not limited to: 

A dry desiccant system will absorb airborne moisture and reduce humidity. One common example of this would be the silica gel packets that are included in many consumer goods to prevent moisture accumulation, such as bags of beef jerky. These can vary in size or quantity to accommodate various purposes. 

A liquid desiccant system absorbs moisture in the ear through a chamber containing liquid water-lithium chloride. It shares the same goal as a dry desiccant system of attracting, trapping, and retaining moisture to dehumidify a space. 

One can also use a refrigeration system to cool softgels. The cold air will prevent excess moisture and preserve the freshness of the product. 

Interested in Creating Your Own Softgels? Check Out These Encapsulation Machines! 

At CapPlus we offer a variety of softgel encapsulation systems to serve different manufacturers’ needs such as making pharmaceutical, nutraceutical, food, and recreational products.  Some of our most popular machines include: 

4” Dual Softgel System

The Dual Softgel System can produce capsules made from both animal gelatin and tapioca starch. Featuring a 120 liter material transfer tank and a 6-plunger medicine pump, this machine can produce up to approximately 28,000 gelatin-based softgels per hour. This makes a perfect solution for small and medium batches as well as research and development projects. 

Learn more about the 4” Dual Softgel System. 

CPT T150 12” System

The T150 is a PLC controlled and touchscreen-operated compact machine that is designed for ease-of-use while saving you valuable production floor space. Designed for both vegetable and animal gelatin, the machine can produce tens to hundreds of thousands of softgel capsules per hour, depending on size. 

Learn more about the T150 12” System. 

CPT T150 10” System

Featuring the same PLC controlled, touchscreen-operated interface and compact design as the 12” System, the T150 10” version offers even more floor space savings with the ability to produce tens of thousands of capsules in an hour’s time. 

Learn more about the T150 10” System. 

Want to take your productivity even further? Check out our 10” T150 Automatic Softgel Encapsulation System Equipment Package.

What’s the Right Softgel Encapsulation System for You? Let Us Help 

Our team wants to help you discover the best softgel encapsulation machine to match your own manufacturing processes and needs. If you would like more information about the production process, equipment specifications, or anything else related to creating high-quality softgel products, contact us anytime. 

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