Softgel Encapsulation Line

• High-Precision Filling System: The machine uses a linear-driven injection system that delivers highly accurate dosing for oils, suspensions, and semi-solid formulations. Filling accuracy can reach up to ±1%.
• High Output Capacity: Depending on the model and configuration, the system can produce from 50,000 to 200,000 capsules per hour. This makes it suitable for large-scale production.
• Low Capsule Defect Rate: The encapsulation system is engineered to reduce common issues such as leakage, improper sealing, or inconsistent capsule shape. It has a rejection rate of less than 2%.
• Multi-Stage Drying System: Our softgel encapsulation line includes tumble dryers and controlled drying tunnels that remove excess moisture from capsules after formation. Proper drying prevents sticking and improves shelf stability.
• GMP-Compliant Design: All product-contact components are manufactured using high-grade stainless steel, meeting GMP standards. The design also supports easy cleaning and inspection.
• Installation, Commissioning, and Guidance: Key components are positioned for easy access, allowing routine maintenance and cleaning. This reduces downtime between production cycles.

Applications

• Pharmaceutical Softgel Manufacturing: Pharmaceutical facilities use softgel lines for an enclosed, easy-to-consume format. This is especially common for oil-based drugs, fat-soluble vitamins, and medicines that benefit from controlled release.
• Dietary Supplement Production: Supplement manufacturers rely heavily on softgel encapsulation for products like fish oil, omega-3, vitamin D, and herbal extracts. This line allows brands to handle multiple formulations.
• Beauty Product Manufacturing: Softgel technology is widely used in the cosmetic sector for encapsulating serums, oils, and beauty supplements. Products such as skin-repair oils, anti-aging formulations, and hair-care supplements often come in this format.

Workflow

• Step 1: Gelatin Preparation: Gelatin is mixed with water, plasticizers, and colorants in a preparation tank.
• Step 2: Gelatin Ribbon Formation: The prepared gelatin is spread into thin ribbons using casting drums.
• Step 3: Fill Material Preparation: Meanwhile, the active ingredient (oil, suspension, or paste) is prepared in a separate tank.
• Step 4: Encapsulation Process: Two gelatin ribbons meet at the die rolls, where the fill material is injected between them. At the same time, the capsule is formed, filled, and sealed in one continuous motion.
• Step 5: Capsule Discharge: Freshly formed softgels are released from the machine and transferred for initial cooling.
• Step 6: Tumble Drying: Capsules enter tumble dryers where surface moisture is removed. This step begins the hardening process and prevents capsules from sticking together.
• Step 7: Tray Drying: Softgels move onto drying trays or tunnels, where controlled conditions gradually remove moisture over time.
• Step 8: Sorting and Inspection: Finished capsules pass through sorting systems to remove defects such as leaks or irregular shapes.
• Step 9: Polishing and Finishing: Capsules are cleaned and polished to improve appearance.