Types of Softgel Fill Formulations
A wide variety of compounds can be incorporated into softgel fills including:
Liquids: Essential oils, flavors, liquid botanical extracts and other hydrophilic ingredients are well-suited for liquid softgel fills. Good examples include fish oil and medium chain triglyceride supplements.
Semisolids: Formulations containing medium viscosity oils mixed with waxes or gelling agents fall into the semisolid category. Softgels containing coconut oil or MCT oil blended to a spreadable consistency are common semisolid fills.
Solutions: Powdered ingredients dissolved in solvents like water, glycerin or alcohol produce solution-type Softgel Capsule fills. Water-soluble vitamins, minerals and herbal extracts are delivered this way.
Suspensions: Undissolvable compounds suspended in liquid carriers comprise suspension fills. Examples are calcium carbonate or green tea powder suspended in liquid.
The fill type selected depends on factors like intended dosage, stability requirements and solubility of active ingredients. Softgels provide versatility to deliver a wide range of compounds.
Manufacturing Process for Softgel Capsules
Softgels are produced using a rotary die process similar to hard shell capsules, albeit with some key differences:
1. Liquid, semi-solid or powder fill material is precisely metered into the lower die cavity of the encapsulation machine.
2. A pre-formed gelatin band fitted into the upper die section is pressed onto the lower die, sealing the fill inside.
3. Excess gelatin is trimmed away from the resulting softgel before it is ejected onto a conveyor belt for drying.
4. Dried softgels are sent through quality control checks like dissolution testing before packaging. Colorants or imprinting may also be added.
Automated, continuous softgel production lines can manufacture millions of capsules per hour. Strict temperature, humidity and cleanroom controls ensure consistent shell quality and product integrity. Computerized machinery improves fill weight accuracy to within a few milligrams.
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