Softgels are becoming increasingly popular in the pharmaceutical and nutraceutical industries due to their ease of swallowing, improved bioavailability, and ability to mask unpleasant flavors. The process of producing softgels is very complex and requires the use of specialized equipment known as softgel production equipment. In this article, we will learn how softgels are produced and the role of softgel production equipment in the production process.
Softgel capsules are gelatin capsules containing a liquid or semi-solid filler material. They are typically made from a mixture of gelatin, glycerin, and water to form a soft and flexible shell. Filling materials may include oils, herbal extracts, vitamins and other active ingredients. The unique nature of softgels makes them ideal for formulations ranging from dietary supplements to pharmaceuticals.
The production of softgels involves several key steps, each of which is accomplished by softgel manufacturing equipment. The following is a detailed description of the process:
1. Formulation Development
Before actual production can begin, a suitable formulation must be specified for the softgel capsule. This includes selecting the correct active ingredient, excipients and determining the appropriate ratio. The formulation must be stable and compatible with the gelatin shell to ensure optimal performance.
2. Gelatin Preparation
The first step in the softgel capsule manufacturing process is the preparation of gelatin, which is derived from collagen of animal origin. Gelatin is dissolved in water and heated to form a homogeneous solution. Glycerin is usually added to the mixture to enhance the elasticity and softness of the final capsule.
3. Setting up the equipment for softgel capsule production
Once the gelatin solution is ready, the softgel capsule production machines can be installed. These machines are designed to automate the entire softgel capsule production process, ensuring consistency and efficiency. Key components of the softgel capsule production equipment include
-Gelatin melting tank: where gelatin is melted and kept at a controlled temperature
-Metering pump: This component accurately meters and dispenses the filler material into the gelatin shell.
-Die Roll: The die roll is the key component in molding gelatin into capsules. It consists of two rotating drums that form the shape of the soft capsule.
-Cooling system: After the capsules are molded, they need to be cooled to solidify the gelatin.
You can learn about this one produced by our company, LQ-RJN-50 Softgel Production Machine
Oil bath type electric heating spray body (patented technology) :
1) The spray temperature is uniform, the temperature is stable, and the temperature fluctuation is guaranteed to be less than or equal to 0.1℃. It will solved the problems like false joint, uneven capsule size which is caused by uneven heating temperature.
2) Due to the high temperature accuracy can reduce the film thickness about 0.1mm (save gelatin about 10%).
The computer adjusts the injection volume automatically. The advantage is save time, save raw materials. It is with high loading accuracy, loading accuracy is ≤±1%, greatly reduce the loss of raw materials.
Reversing plate, upper and lower body, left and right pad hardness to HRC60-65, so it is durable.
4.Capsule Forming
Softgel capsule manufacturing equipment uses a die roll process to form capsules. Gelatin solution is fed into the machine and extruded through the die roll to form two sheets of gelatin. The filling material is then injected between the two pieces of gelatin and the edges are sealed to form individual capsules. The process is highly efficient and can produce thousands of software capsules per hour.
5.Drying and cooling
After the capsules are molded, they are fed into a drying and cooling system. This step is critical to ensure that the capsules retain their shape and integrity. The drying process removes excess moisture, while the cooling process allows gelatin to be used to solidify and form a stable and durable softgel capsule.
6. Quality Control
Quality control is an important part of softgel capsule production. Each batch of capsules is tested for a variety of parameters, including size, weight, fill level and dissolution rate. Advanced softgel production facilities are equipped with monitoring systems to ensure that the production process strictly adheres to quality standards.
7. Packaging
Once the softgel capsules have passed quality control, they are packaged for distribution. Packaging is an important step as it protects the capsules from environmental factors and ensures their shelf life. Depending on the target market, softgels are usually packaged in blister packs, bottles or bulk.
Investing in softgel capsule production equipment can offer manufacturers multiple advantages:
-High efficiency: Automated machines can produce large quantities of softgel capsules in a short period of time, thereby reducing labor costs and increasing productivity.
-Consistency: Softgel manufacturing equipment ensures consistency in capsule size, shape and fill volume, which is critical to maintaining product quality.
-Flexibility: Many modern softgel capsule manufacturing machines can accommodate a wide range of formulations, allowing manufacturers to diversify their product offerings.
-Waste Reduction: Advanced technology minimizes material waste during production, making it more cost-effective and environmentally friendly.
The production of softgel capsules is a complex process that requires careful formulations, precise production techniques and specialized equipment. Softgel capsule production equipment plays a vital role in this process, enabling manufacturers to produce high-quality capsules efficiently and consistently. By understanding how softgels are produced and the technology behind softgel manufacturing equipment, companies can better meet the growing demand for these popular dosage forms in the pharmaceutical and nutraceutical markets. Whether you are a manufacturer looking to invest in softgel production technology or a consumer interested in the benefits of softgels, this knowledge is key to understanding the world of softgel production.
Post time: Nov-11-2024