Softgels, also known as soft gelatin capsules. These types of capsules are becoming popular among the supplement’s consumers because of their ease of usage. Softgels are widely used in the pharmaceutical and supplement industry.
These softgels deliver various types of medications, vitamins, and other dietary supplements. Generally, softgels contain liquid or semi-liquid types of active ingredients which is encapsulated inside the outer shell, which is made up of gelatin
To understand the functionality of softgels, it is important to understand how softgels are made. The production of softgels involves many key steps and specialized equipment. Let’s understand these steps in detail and light up on the production of softgels.
Step 1: Preparation Of Outer Shell (Gelatin)
The process of making softgels starts with the preparation of gelatin which is the core material for the outer shell. The material required for the preparation of the outer shell is gelatin, water, glycerin (or any plasticizer like sorbitol), and flavorings.
After measuring the amount of gelatin, water, and glycerin according to the formulation. These ingredients are mixed properly in the container. The mixture is generally heated to 140 degrees to 160 degrees Fahrenheit. This heating helps the mixture to dissolve gelatin completely.
Now, the process of deaeration starts, this process involves removing any air bubbles present in the mixture that can cause damage to the production of the outer shell.
If necessary, a flavoring can be mixed with the gelatin mixture. This flavoring can enhance the taste of the softgels. However, this step is optional.
Sometimes, stabilizers and preservatives are added to the gelatine mixture to enhance the shelf life of the softgels.
Step 2: Formulation Of Active Ingredient
The active ingredient is the primary substance that is intended to produce the desired therapeutic effects. To formulate the active ingredient properly, we need carrier oils, preservatives, stabilizers, and other excipients along with active ingredients.
Now, all the ingredients will be measured according to the formulation and mixed properly. If needed, heat can be supplied to mix the mixture of active ingredients properly.
Similar to the previous step, this mixture will undergo the deaeration step to remove the air bubbles that may harm the mixture.
Step 3: Process Of Encapsulation
Now, the prepared gelatin mixture goes into the encapsulation machine where the mixture will be transformed into two shell-like structures.
Now, the mixture of active ingredients will be pumped into the machine which will inject the active ingredients mixture between those two shell-like structures.
As the mixture goes between those two shell-like structures, another machine will seal the active ingredient between those two gelatin shells. This will create the individual softgel capsule.
Step 4: Drying Of Softgels
Just after the process of encapsulation ends, softgels will be transferred to another container or rotating drum with control atmospheric pressure, temperature, and humidity to remove the moisture from the softgel.
After this, all the softgels will be spread out on drying trays and placed into the drying chamber. The softgels will be left here for days to remove the moisture completely from the softgels. This will help to achieve the desired consistency and hardness.
Step 5: Quality Check Of Softgels
Quality measures and inspection are necessary at each step. There are several methods to measure and maintain the quality of softgels. Automated high-speed cameras can be used to inspect the quality of softgels accurately.
Some other tests can also be taken into consideration to ensure the uniformity, weight, and consistency of the softgel.
Benefits Of Softgels Over Other Alternatives
Softgels offer several benefits over other alternatives like tablets and capsules present in the market. Some of the key advantages are:
- Prevention From Unpleasant Odor And Taste: The taste and odor of active ingredients present in the softgel can be unpleasant. The outer shell of softgels helps prevent the unpleasant odor and taste.
- Better Absorption Rate: Softgels encapsulate the liquid or semi-liquid-based formulation. The liquid active ingredients can absorb better in comparison to solid active ingredients. This increases the absorption of fat-soluble nutrients and medications.
- Protection Of Core Ingredients: Softgels help protect active ingredients from air, atmospheric moisture, and light. These factors are responsible for degrading the quality of vitamins, minerals, and medicines. This extends the shelf life of the active ingredients.
- Pre-measured Dosage: Softgels come with a pre-measured dosage of different ingredients which ensures the consistency of softgels. This ensures the exact amount of active ingredients in each softgel.
- Ease Of Swallowing: Softgels are easier to swallow in comparison to capsules and tablets. This is because of the smooth and soft surface of the softgels.
- Convenience: Softgels offer convenient ways to take medication and supplements as they are easy to carry and consume. Softgels do not require any type of mixing or measuring while taking medication.
Quality Standards While Manufacturing Softgels
Custom softgel manufacturing for supplements should follow certain quality standards like GMP standards. These standards cover various aspects like the selection of raw materials, manufacturing process, regular maintenance of equipment, and product testing.
The quality of the raw materials should meet the specified standards. Raw materials like gelatin, plasticizers, and active ingredients should be tested for their purity and potency. The finished products should undergo an extensive quality check to ensure the quality and purity of softgels.
The packaging and labeling of softgels must meet the quality standards and regulatory requirements. This ensures product identification and information for the consumers.
The End Note
In short, the process of making softgels includes many steps. The process starts with the preparation of the outer shell which is generally made up of gelatin. After that, the mixture containing the active ingredient is made.
Then, the process of encapsulation starts which includes the filling of a mixture of active ingredients between the outer shell. Now, the drying of these softgels starts. After the quality check of softgels, softgels are ready to dispatch.
