What is a Softgel Encapsulation Machine and How Does It Work?

How well do you understand the softgel encapsulation machine? In addition to its working, this article will explain the parts that make it. We will also guide you in maintaining the filler and explore its various uses. Finally, we will help you choose the best one for your needs.

What is a Softgel Encapsulation Machine?

A capsule encapsulation machine is a device that produces, fills, and seals soft gel capsules. Before proceeding, let’s answer this popular question. What is a soft gel capsule?

Soft gel is soft gelatin in full. It describes a type of soft capsule made from gelatin. Gelation is a protein product derived from boiling animal bones, skin, and tendons.

Soft gel capsules are translucent encapsulations used to package various products. They are edible and easy to dissolve, making them suitable for medications, nutritional products, herbal extracts, etc.

A soft gel filling machine makes and seals these capsules. As a result, its design and working differ from that of a hard gelatin type. We will examine its parts and working principle shortly. Before that, let’s understand its different versions.

Semi vs. Fully Automatic Softgel Encapsulation Machines

The soft gel capsule filler is either partially or fully automatic. Each type has an application it best suits, depending on production needs, business size, and budget.

Semi-Automatic Encapsulation Machine

This type combines automatic and manual steps. In other words, the operator will perform some tasks when using one. It costs less than the fully automatic type but has a low output, making it unsuitable for scaling production.

Automatic Encapsulation Machine

An automatic encapsulation machine works without requiring you to intervene: you only need to oversee its operation and adjust setting. As a result, you achieve higher outputs when using one, making it best for large-scale manufacturing.

Softgel Encapsulation Machine Parts

Many parts make up a soft gel capsule machine, especially since it has several other functions besides filling. We grouped them into primary auxiliary parts for easier understanding.

Main Parts

• Material Tank – this part holds the fill material. As such, it’s typically stainless steel to comply with cGMP and FDA requirements
  
• Gelatin Melting Tank – the tank melts and mixes the gelatin to produce the desired composition. Some filler types include it in their construction
  
• Material Feeding Pump – the pump feeds material from the hopper to the filling station
  
• Gelatin Spreader box – the box spreads the gelatin into a thin film for capsule formation and encapsulation. Located on either side of the filler
  
• Injection Wedge – a wedge-shaped part that warms the web to the required temperature
  
• Cooling Drum – also located on the right and left side, it rotates and cools the gelatin
  
• Chilling System – some filler types include a chilling system to sustain the gelatin temperature within the required limits
  
• Lubrication Rollers – located on either side, they flatten the gelatin, eliminating imperfections
  
• Tooling System – it contains two differently shaped dies with varying configurations. Their shape determines the type of capsule
  
• Stripper Roller and Die Roll Brush – the stripper removes capsules from the web while the brush removes stuck capsules from the die rolls
  
• Discharge Chute – the discharge chute receives capsules coming from the die system and sends them to the conveyor
  
• PLC Controls – this part allows you to set various parameters and is usually a touchscreen HMI, with the modern filler featuring a full-color interface
  

Auxiliary Parts

These are auxiliary components. They usually do not form part of the capsule production and filling process but are crucial to their production. They include:

• Capsule Polisher – for cleaning and polishing filled encapsulations
  
• Capsule Sorter – it works by separating the encapsulations based on size or shape
  
• Capsule Inspection System – comprises vibratory components, sensors, and other parts. It inspects the capsulations to ensure they meet set standards
  
• Capsule Pulverizer – it reduces wastage by grinding damaged capsules to recover gelatin and the fill material

How Does a Softgel Encapsulation Machine Work?

The working of a soft gel capsule filler machine involves various stages. They take in the raw material (gelatin) and form capsules to seal and protect the ingredients.

The machine synchronizes these actions, ensuring efficiency and precision. The modern fillers also come with various advancements, including controls, making them more straightforward to operate.

Outputs vary by machine design and size. Most automatic fillers seal thousands of capsules every minute, with large systems attaining 300k pieces per hour or more.

Softgel Encapsulation Machine Process

Filing soft gelatin capsules is long and composed of many steps. It includes capsule production, unlike hard gelatin filling, where they come ready to use. We tracked the process from start to finish.

1. Gelatin Preparation

The process starts with preparing the gelatin formulation. This process occurs in the gelatin melting and mixing tanks. The gelatin is in the form of thick syrup and ready to roll into a film.

2. Fill Material Preparation

Meanwhile, the liquid or semi-liquid fill material is ready for use. The material may be a dietary product or supplement, medicinal drug, or other substance, including industrial chemicals.

3. Encapsulation Steps

The capsule formation and sealing process can now begin. The following steps describe what occurs in each stage.

• The capsule formation and sealing process can now begin.
  
• A gelatin ribbon moves on the machine’s either side to the tooling section
  
• Vacuum pressure pulls the ribbon into the die, causing it to form a cavity
  
• At the same time, the fill material travels down to the rotating die rollers
  
• The die system squeezes the two ribbons, sealing the fill material inside
  
• This action forms the capsules, which take the shape of the tooling die’s cavity
  
• The formed capsules fall into the discharge chute
  
• From here, a conveyor system moves them to the drying stage
  

4. Drying Stage

In the drying stage, the capsules first undergo a tumble drying process. This procedure removes excess moisture by blowing dry air over a tumbler. Later, they will enter a tunnel where complete drying takes place.

5. Sorting and Inspection

After drying, a device automatically separates the good and bad capsules by color, weight, thickness, and other criteria like shape. The sorting process can also be manual but more laborious.

6. Cleaning and Polishing

Finally, another device cleans and polishes the capsules to remove residual oils and other materials. Finished capsules are labeled and packaged for storage or dispatch to customers. Packaging options include blister packs, tins, glass jars, and more.

How to Maintain a Softgel Capsule Filling Machine

The soft gel filler suffers wear and tear like any other electromechanical device. It can also break down, but more frequently if you neglect it. The following steps explain its maintenance to avert unnecessary downtimes.

Regular Inspections and Cleaning

Routinely inspect the machine to ensure various components are in good condition. These include moving parts which wear faster and are more likely to fail, such as gears and belts.

Regular cleaning is also essential. Use vacuum pressure or compressed air to remove debris from surfaces and hidden areas. You may also need to wash removable components with brushes or other materials.

Lubricate Moving Parts

Regularly add lubricant to oil moving parts, especial the die roll assembly and gelatin drum must. Be sure to follow the manufacturer’s recommended time-frames. It helps reduce friction, preventing early wear or damage. It also ensures a smooth operation..

Adjustment and Calibration

Proper adjustments ensure the machine operates efficiently. Align gears, dies, and other parts like wedges occasionally. Calibrate it for precision, setting appropriate values for speed, temperature, and other parameters.

Softgel Encapsulation Machine Applications Today

You can use the soft gel filler to manufacture various products, from medications and supplements to cosmetics. Typical applications include those mentioned below.

Pharmaceuticals

It helps produce soft gel capsules for carrying various medications, such as cannabinoids, into the human body. They include both oral and topically applied formulations.

Veterinary Products

Soft gel capsule manufacturers also use the machine to produce animal drugs. These include oral and topical medications, using soft and easy-to-use encapsulations.

Nutraceuticals

The machine fills several dietary products, including fish oils, in translucent capsules. The encapsulations offer several benefits: they are soft, tasteless, and without odor, making them easy to use.

Packaging Cosmetics

They package cosmetic products in fast-softening encapsulations. These can be injectable products used on the face, including the lips, and check bone fillers. Others are stick-on creams, shower gels, massage oils, and soaps.

Factors When Choosing a Softgel Encapsulation Machine

You can only get the most out of your filler if you select the right type. In that regard, you must understand the factors to consider and the features to look out for, as explained below.

Production Capacity Needs

How many capsules per hour can you produce with it and how well does it fit your business? Ensure you have a filling device that meets your current needs and, if looking to expand later, future output requirements.

Capsule Size and Shape

Select a device that can handle the capsules you intend to produce. Manufacturers usually indicate the information on the technical specifications list. You can also request them to customize one for your application.

Ease of Use

Above all, ensure the machine is easy to use. This requirement depends on the unique design options. For instance, using an automatic machine with a touchscreen interface is more effortless. Its parts must be easy to change, too.

Standards Compliance

Softgel capsule filler manufacturers adhere to various industry standards when making the device. These standards define safety and sanitation requirements, among other specifications.

They include Current Good Manufacturing Practices (cGMP), Federal Communications Commission (FCC), and Restriction of Hazardous Substances (RoHS). You also want it compliant with ISO standards and CE-marked.

Other Specifications

Other essential considerations include the machine’s power needs (consumption), mold sizes, accuracy, and noise levels. You want these within the desired limits.

Consider its construction and whether it includes optional sections like the gelatin melting tank. Ensure its dimensions suit your preferred size, too.

Conclusion

Softgel encapsulation machines seal liquids and semi-solid materials. As such, they differ from hard-gel types in many ways, from parts to operating mechanisms. You can use the machine to manufacture various products, including CBD oil, medications, dietary supplements, etc. When buying one, ensure it has all the needed features and meets industry standards.