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FAQ

Softgel FAQ

How are softgels made?

A softgel is commonly used as an oral dosage form for medicine or supplements similar to capsules. It’s also the same process used to make paintballs. Softgels consist of a gelatin shell surrounding a liquid or paste fill. The softgel shell is a combination of gelatin, water, opacifier and a plasticiser such as glycerin or sorbitol.

Softgels are produced in a process known as encapsulation using a rotary die encapsulation process. Two flat ribbons of gelatin are brought together on a twin set of rotating dies. The dies contain recesses manufactured to a specific size and shape (oval, oblong, etc) which cut out a two-dimensional shape in the gelatin ribbon and form a seal where the two sides meet. As the die begins to cut out the shape in the gelatin ribbon a precise dose of fill material is injected causing the two flat ribbons to expand into the die pockets. After which the dies rotate and seal the fill in the gelatin form.

How much does it cost to make softgels?

Depending on how many softgels you want to make determines the size and speed of the softgel encapsulator you will need. This setup can range from just under $200,000 to over $1M. We have a system to suit every need – from start-up, to R&D, to high volume production.

What equipment do I need?

To make softgels you will need a softgel encapsulator, tooling (rotating dies in the sizes and shapes you need), a gel melting system, gel melting tank(s), fill transfer tank(s), chiller, and tumble dryers. The CPT 4” softgel system comes complete with everything you need to get started making softgels, smaller batches, and R&D. You may also need options and auxiliary equipment such as color mixing systems, drying trays and dollies, drying tunnels, stone mill, vacuum homogenizer, visual inspection, sorting, and polishing machines, etc.

Are softgels easy to make?

CapPlus can provide complete installation and training. If you’re a first timer starting up a nutraceutical line or paintball business our 25 years of experience can help you with everything you need to become familiar and confident in the softgel making process. If you’re an experienced softgel manufacturer you can be rest assured that we have seen it all and can confidently help guide and direct your complete softgel setup.

What is the most popular softgel encapsulator for first timers?

Our most popular softgel encapsulator for start-up softgel manufacturers in the 4” softgel complete setup. This economical solution comes complete with a 4” softgel encapsulator, gel melting/transfer tank, fill transfer tank, chiller, and 2 tumble dryers. This complete system will let you make softgels from start to finish. Depending on the humidity of your production location drying times will vary and you may need to enhance your drying with additional tumble dryers, drying tunnels, humidity controls, etc.

Where do I get the ingredients?

Upon purchase of a softgel encapsulation system we can provide you with softgel material providers.

How do I make Vgels?

CapPlus provides softgel encapsulation equipment specifically designed for Vgel formulations. We can also connect you to a newly available Vgel formula that is less expensive and requires no contract. The combination of these two solutions will help you easily and economically make Vgels.

Can I get financing?

Yes. We offer financing through a partner.

Does CapPlus have experience with other softgel manufacturers?

We have 25 years of experience in helping softgel clients to be successful. From startup to large manufacturers. From pharmaceutical, to nutraceutical, to paintball. From independent brands to contract manufacturers. We’d love to provide you with the products and services that can help your company be successful as well.

Vgel FAQ

What is a Vgel?

A Vgel is a type of softgel that is commonly used as an oral dosage form for medicine or supplements. Their smooth surface makes even large softgels easier to swallow and are durable, reliable, and popular with consumers. Softgels consist of a gelatin shell surrounding a liquid or paste fill. The softgel shell is a combination of gelatin, water, opacifier and a plasticiser such as glycerin or sorbitol. Common softgel gelatin shells are made from pork, bovine, or fish derivatives. Growing consumer markets wish to avoid consuming such gelatin for any number of reasons including religious, cultural, or vegetarian concerns. To meet those needs, Vgel shells are becoming more and more popular as they are made from plant sources or ingredients such a tapioca (starch).

Vgel formulations come in different varieties – Which one is right for you?

Popular Vgel shells are made from ingredients such as tapioca or seaweed. While both work effectively in encapsulation and can be marketed to Vgel target markets, tapioca is generally less expensive and easier to work with. Thus budget limitations that have been the primarily barrier of whether or not to add vgel products to your product line are now easier to accommodate. CapPlus can easily connect you to a newly available starch formula that is less expensive and requires no contract.

How are Vgels made?

Softgels are produced in a process known as encapsulation using a rotary die encapsulation process. Two flat ribbons of gelatin are brought together on a twin set of rotating dies. The dies contain recesses manufactured to a specific size and shape (oval, oblong, etc) which cut out a two-dimensional shape in the gelatin ribbon and form a seal where the two sides meet. As the die begins to cut out the shape in the gelatin ribbon a precise dose of fill material is injected causing the two flat ribbons to expand into the die pockets. After which the dies rotate and seal the fill in the gelatin form. Vgel formulas are thicker in viscosity than standard gelatin and specific equipment is needed to manage the temperature changes required during the production process.

How much does it cost to make Vgels?

Depending on how many Vgels you want to make determines the size and speed of the softgel encapsulator you will need. CapPlus has encapsulation systems to suit every need – from start-up, to R&D, to high volume production. This setup can range from under $200,000 to over $1M.

Where do I get the ingredients?

Upon purchase of a softgel encapsulation system we can provide you with vgel material providers.

What equipment do I need?

To make Vgels you will need a softgel encapsulator, tooling (rotating dies in the sizes and shapes you need), a gel melting system, gel melting tank(s), fill transfer tank(s), chiller, and tumble dryers. You may also need auxiliary equipment such as color mixing systems, drying trays and dollies, drying tunnels, stone mill, vacuum homogenizer, visual inspection, sorting, and polishing machines, etc.

CapPlus provides softgel encapsulation equipment specifically designed for Vgel formulations. We can also connect you to a newly available Vgel formula that is less expensive and requires no contract. The combination of these two solutions will help you easily and economically make Vgels.

Can I use my current softgel production equipment for Vgel production?

Yes. Vgel specific modifications can be made and Vgel specific equipment can be purchased so that you can easily convert your standard softgel encapsulator to a dual softgel/Vgel encapsulator. You may also want to strongly consider dedicating an encapsulator to Vgel specific production in order to meet growing Vgel market demand.

Does CapPlus have experience with other softgel manufacturers?

We have 25 years of experience in helping softgel clients to be successful. From startup to large manufacturers. From pharmaceutical, to nutraceutical, to paintball. From independent brands to contract manufacturers. We’d love to provide you with the products and services that can help your company be successful as well.

Vgel marketplace & opportunities

Softgels are an increasingly popular dosage form, especially in the fast growing nutricuetical market. Vgels enable you to meet this demand with a non-animal shell that will satisfy your customers’ vegetarian, religious, and cultural needs

Brass Tacks - What does it take to start Vgel production?

Vgel production equipment and formulas are available today. Contact CapPlus today for a recommendation based on your budget and production needs.

Can I get financing?

Yes. We offer financing through a partner. Why worry about depleting your budget when it only takes dollars a day for you to get started.