Softgel Manufacturing

Softgel Manufacturing

We have capabilities to manufacture any nutraceutical softgel formula. From sourcing each ingredient in your formula, to post-filling inspection — we do it all at the best prices and the fastest lead times. We have the experience to help you formulate a new product for your target audience, or discuss with you how to properly scale your manufacturing. As your partner, it is our job for long-term softgel manufacturing success.

SMP stands for Supplement Manufacturing Partners. Our team is dedicated to being your partner in most efficiently manufacturing your growing vitamin business to scale. You can see our FDA registration and GMP certification here.

Custom Softgel Manufacturing

SMP Nutra is a leading softgel manufacturer in the USA. Whether you have a formula prepared or want to create one, our team can help you with that process from beginning to end.

The Softgel Manufacturing Process

Softgel encapsulation is a common practice, as it is one of the most popular types of nutraceutical products. The process of producing a softgel capsule is comprised of six main steps.

Preparing The Gelatin

To begin, a machine will melt a large quantity of gelatin along with several other components. Warm water is typically used to achieve this. Once the gelatin turns into a large gel mass it will be ready.

Fill Material Preparation

Fill materials for softgels come in a variety of forms, such as liquids, oils, suspensions, or semi-solids. The fill materials are mixed and milled in a processing tank to form a fill mass. This requires equipment such as processing tanks, sieves and mills, and vacuum homogenizers.

Encapsulation

Here the mix is turned solid as the casting drum cools and solidifies the gelatin during rotation. The mix is then fed through a set of ribbon rollers and begins to take the shape of the softgel. After the shape is formed, the softgel is ejected from the ribbon rollers.

Drying

Following encapsulation, the formed softgel capsules fall onto a conveyor. In this step, the softgel capsules are directly transferred into a tumble dryer by the conveyor. The tumble dryer works to remove any excess moisture on the softgel capsules, allowing the shell to shrink and making the softgel more firm and durable.

Inspection

Following the completion of the drying stage, the softgel capsules will be transferred to the inspection station for quality control. The products need to be inspected to find and remove any undersized or oversized, deformed, or leaking softgels.

Sorting

Sorting machines are designed to provide visual inspection and sorting of softgel capsules. They automatically inspect the entire surface of the softgel capsules and sort out defectives based on color, shape, thickness, or diameter requirements.

Cleaning and Polishing

After sorting out qualified softgels, a polishing machine is then used to remove any oil residue or debris from the softgel surface. This is to give the softgel its traditional shape and look.

Bottling & Shipment

The softgels are now ready to be poured into their packaging, labels applied to them, and prepared to be sent out. The softgel manufacturing process is now complete.

Gelatin Softgel Components

When manufacturing softgels that are gelatin-based there are four main components that make up the softgel shell:

• Gelatin — The gelatin can either be plant-based or animal-based depending on your formula.
• Water — Water is used to help make the gelatin formula pourable during the manufacturing process. It also acts as a holding agent to keep the formula safely inside of the softgel.
• Plasticizer — Plasticizer is used to make the shell elastic and pliable. As well, it is a means to minimize brittleness and protect the softgel from cracking.
• Additives — Additives such as opacifiers, colorants, flavors, sweeteners, and preservatives are added to the softgel as needed during formulation. Softgels may also be coated with a variety of polymers for other applications.

Unique Softgel Manufacturing Attributes

Softgels are a common form of nutraceutical encapsulation. They have mass appeal due to being able to be customized to nearly however you want. Some of the most important factors about softgels you may be able to alter when producing your formula include:

• Color — The color of a softgel can be modified to better match the contents of it.
• Size & Shape— Produce the perfect sized softgels that are both easy to swallow and capable of delivering the formula's blend.
• Vegan-Friendly Options — Softgels can be made with vegan-friendly ingredients to reach a larger audience.

Private Label Stock Softgel Formulas

SMP Nutra maintains a large selection of stock softgel formulas you can order for your brand today, including fish oil, krill oil, algal oil, cod liver oil, salmon oil, CoQ10, astaxanthin, calcium, aloe vera, vitamin D3 + K2, and more. View all stock softgel formulas here.

SMP Nutra Wants To Be Your Softgel Manufacturer

If you have a great formula that you want to be produced as a softgel, work with SMP Nutra and we can get your softgels produced. Here at SMP Nutra, we have streamlined the process for you and take care of all the communication needed for your softgel capsule formula.

The softgel manufacturing process can be tricky, but with the right equipment, it will be a breeze. We are confident we can fulfill all your softgel manufacturing needs and we would be the best partner for you and your brand. Request a softgel manufacturing quote today.

Softgel Manufacturing FAQ