Learn How to Make Vgels at Your Production Facility 

In the softgel industry, some refer to softgel products that are made with a vegetarian or vegan shell as “vgels”. This provides a suitable alternative for people who live a vegetarian or vegan lifestyle. 

Today we’re going to cover the key aspects of manufacturing vgels at your own facility. If you would like to learn more, visit our FAQ page where we offer more insights into softgel and vgel production. 

What Are Vgel Shells Typically Made Of? 

The industry standard for most softgel pharmaceuticals is animal-based gelatin. Usually, it is sourced from cows or pigs. Instead, vgels are made using a plant-derived source, such as tapioca starch or seaweed. The ingredient is processed in a way that mimics the appearance, texture, and functionality of regular gelatin. 

Vgel Production 

Vgels can be produced using the same equipment that you would for softgels. However, there are some key differences to consider. 

Temperatures

Gelatin processing temperature range from 60C-80C. Conversely, tapioca starch requires a higher processing range of 80C-100C. Unless made specifically for producing vgels, most softgel production equipment will require some modification in order to successfully make starch-based softgel.  

Equipment Needed

As we stated above, manufacturers can use the same equipment for vgels and softgels (though some modification may be necessary). The basic equipment you will need includes: 

• Softgel encapsulator
• Toolset
• Gel melting system and tank 
• Fill transfer tank 
• Chilling unit
• Tumble dryers
• Drying trays and dollies

Other auxiliary equipment you might need, depending on your production demands could also include:

• Color Mixing equipment
• Drying tunnels 
• Vacuum homogenizer 
• Quality assurance equipment (i.e., moisture analysis device, sorting system, polishing machinery, etc.) 

Vgel-specific Equipment Modifications

At CapPlus, we are happy to connect our customers with vgel specific machinery that has proven successful. However, we also understand that finances sometimes dictate working with what you already have. If your current equipment cannot facilitate the requirements for vgel production, here are some modifications that we have found necessary: 

• Higher power mixing motors
• Higher wattage heating elements in mixing system
• Hard line transfer tubing to handle higher pressure for transfer
• Heating tape to keep transfer pipes hot 
• Updated PLC programming to allow for higher temperatures
• Variable speed for tumble dryers to tumble more gently at the start 

Formulas and Ingredients 

As with any pharmaceutical, a vgel formula and ingredients are the most critical aspect of actually making the finished product. Today, many ready-to-use formulas are readily available through a variety of channels. A customer-focused equipment retailer should also be able to provide you with these resources. 

The Manufacturing Process 

Whether using an animal or plant-based shell, the process for manufacturing softgels follows a straightforward 4-step encapsulation process: 

1: Ensure Correct Room Conditions (Humidity and Temperature)

Vgels, even more so than animal based softgels, are especially sensitive to Humidity. Not having humidit yunder control can prohibit the production of vgels. Once ideal humidity levels are achieved, it is also important to keep the room at an acceptable temperature. This ultimately becomes a push/pull situation between the A/C system and the dehumidifier, and so it may be important to seek the advice of an expert when selecting this equipment for your production room. 

2: Creating and Filling Shells

Two ribbons of vgel are created and spun on a pair of rotating drums. Here, compensating for temperature differences is essential. Once it comes time to form the shell, the ribbons are cut and joined to create a seal as the  liquid filling is injected into the shell to form the shape.  

3: Tumble Drying 

Once formed and cut from the ribbon, the vgels are conveyed to tumble dryers to remove moisture from the shell. 

4: Tray Drying

As the final step, the vgel units are placed onto trays and then put in a drying room or drying tunnels for an additional 24-48 hours. This helps to bring the moisture content in the shell to an acceptable level for packaging and shelf stability. 

Vgel Quality Control 

Each manufacturer will have their own protocols for quality control. No matter the specific details of one’s quality control process, softgels should be checked for leaks, moisture and water activity, as well as shell hardness. Some equipment, depending on your own processes, that might be relevant include: 

• Hardness testers
• Moisture analyzers 
• Leak detection systems 

Vgel Packaging 

Vgels are typically packaged either in a bottle, carton, or blisterpaks. 

Depending on your packaging preferences, you may also need some or all of the following equipment: 

• A conveyor to move the packaging along the production line 
• A counter to fill containers by quantity rather than weight 
• For bottle packaging: A bottle unscrambler, capper, labeler and induction sealer for lids
• A cartoner for paper packaging 
• A blisterpak machine for blister packaging 
• Dessicant or cotton inserter for bottle packaging 

Get Your Own Vgel Production Equipment Today 

At CapPlus, we strive to provide pharmaceutical manufacturers with industry-leading packaging, production, and quality control equipment for their vgel products. To learn more about getting the right equipment for your own vgel manufacturing, as well as more information on formulas and ingredients, contact us anytime.