From fish oil to probiotics, softgels provide a versatile, patient-friendly delivery system for a wide range of healthcare products. However, for manufacturers, ensuring consistent and high-quality softgel capsule production depends on a critical piece of equipment: the softgel encapsulation machine.
With such a large investment, it can be overwhelming to select the ideal one. This guide will be your roadmap, helping you make an informed decision and unlock the potential of softgel encapsulation for your business.
What Are Softgel Capsules?
Softgel capsules are a type of oral dosage form for medications or supplements. They consist of a liquid or semi-solid filler encased in a soft, gel-like shell.
Many consumers increasingly favour softgels over traditional tablets. They are easier to swallow because of their smooth, flexible texture. In addition, the shell of a softgel capsule can effectively mask the odour of the medication or supplement.
What Are Softgel Encapsulation Machines?
Softgel encapsulation machines are highly specialised equipment responsible for the mass production of convenient softgel capsules containing medicines, vitamins and nutraceuticals. These machines operate with great precision, transforming raw materials into finished softgels through a multi-step process. Let's delve deeper into each step:
- Step 1: Firstly, filling materials such as medicines or health products are stored in a specialised hopper. The machine then uses a metering pump to accurately measure and extract the filling material from the hopper.
- Step 2: Two separate chambers in the softgel encapsulation machine prepare the gelatin solution. The chambers control the temperature and flow rate to form a continuous band of gelatin solution.
- Step 3: When the two gelatine bands converge, a precisely designed injection wedge deposits a pre-measured dose of filling material between the two gelatine bands
- Step 4: Engraved metal moulds are mounted on a rotary conveyor belt. These moulds come in different shapes and sizes and determine the final design of the capsule. As the conveyor belt rotates, bands of gelatine pass through the moulds. The mould then applies pressure to seal the gelatine layers together, encasing the fillings and forming the final soft capsule shape.
- Step 5: Freshly moulded softgels may contain excess moisture. The machine usually consists of a drying chamber that removes the moisture through controlled temperature and airflow. Finally, the softgel capsules may go through a polishing stage to achieve a smooth, uniform finish.
Who Needs Softgel Capsule Encapsulation Machines?
Softgel capsule encapsulation machines are the silent heroes behind patient-friendly softgel capsules. These machines play a vital role in several industries that rely on precise encapsulation of liquid or semi-solid formulations. Let's take a look at some of the major industries that use softgel technology.
Pharmaceutical Industry
The pharmaceutical industry is still a major user of softgel encapsulation machines. Softgel capsules are popular among patients and healthcare providers because of their multiple pharmaceutical benefits. Firstly, softgel capsules are a boon for those who have difficulty swallowing large tablets. For example:
- Children's painkillers such as ibuprofen or acetaminophen
- Chewable multivitamins
- Medications for older patients who have trouble swallowing pills
Also, softgel encapsulation is effective in masking unpleasant flavours and improving palatability:
- Fish oil supplements with a fishy flavour
- Certain antibiotic drugs known for their bitter taste
Nutraceutical Industry
Softgels offer a hassle-free, convenient way to provide a daily dose of essential vitamins or other nutritional supplements. Now, people no longer have to fumble with taking multiple capsules or dealing with a jumble of powders. An easy-to-swallow softgel simplifies the process. For example, a multivitamin containing several essential vitamins and minerals can be encapsulated in a single softgel.
Cosmetic Industry
The benefits of softgel encapsulation are no longer unknown in the cosmetics sector. Softgel capsules allow for the precise application of active ingredients to specific areas of the skin. Some of the common cosmetic products that utilise softgel encapsulation technology are:
- Retinol serums
- Acne spot treatment products
What's more, softgel encapsulation prevents the degradation of subtle ingredients in cosmetics, such as vitamin C serums and antioxidants.
What Are the Key Considerations before Buying a Softgel Encapsulation Machine?
Softgel encapsulation machines can be a game changer, transforming liquid or semi-solid formulations into user-friendly capsules. But before diving headfirst into this exciting investment, here's an important checklist for your consideration.
- Size and Shape Matters
Softgel capsules usually come in various shapes and sizes (oval, round, oblong).So,you should ensure the softgel machine you choose can produce capsules of the exact shape and size you want.
- Consider Your Production Volume
Before purchasing a softgel encapsulation machine, carefully consider your current and future production needs. The output capacity of machines can vary, so choose a machine that matches your production goals.
- Manual, Semi-Automatic, or Fully Automatic?
Softgel encapsulation machines come in different automation levels: manual, semi-automatic and fully automatic. Before making the final decison, consider your budget and the level of automation you need. For small batch production, manual or semi-automatic machines may be enough. However, for high volume production, a fully automatic machine can greatly increase efficiency.
- Accuracy is Critical
When filling softgel capsules, accuracy is super important. So, you need to understand the capabilities of your machine's dosing system and make sure it can handle the materials you choose for consistent filling. Accuracy requirements may vary depending on the type of product you are encapsulating.
- Go for a Reliable Manufacturer and Good Service
When choosing a softgel filling machine, always research the reputation of your chosen manufacturer first. Good after-sales service and readily available spare parts are key to smooth operation. Don't choose a machine if it has limited support or spare parts availability.
- How Much Are You Willing to Invest?
Incorporating a softgel filling machine into your production line is a major investment. You'll need to set a realistic budget and compare pricing options from different manufacturers to find the most cost-effective solution.
- Does the Machine Meet Certain Regulations?
The capsule encapsulation machine you purchase should comply with the relevant safety and cGMP regulations for your industry. Safety and quality come first! Make sure that the machine you choose meets the necessary regulatory requirements.
- Do You Have Enough Space for the Machine?
A Softgel encapsulation machine may have a big footprint. Therefore, before purchasing, please measure your available space to ensure that the machine can be installed and operated without any problems. This will somehow avoid production bottlenecks.
Final Takeaways
Softgel capsule sealers offer powerful and versatile solutions for a wide range of industries. Carefully assess your production needs, the capsule format required, and your budget. Look for a reputable machine manufacturer with strong after-sales support . With these considerations in mind, you'll be able to choose the ideal softgel capsule encapsulation equipment and drive your pharmaceutical business forward.