The production process of soft capsules is subject to very strict quality control at every stage of the process:
1
Selection and quality verification of raw materials for production
The completeness and consistency of the documentation is verified and each of the raw materials is evaluated according to the analysis plan
2
Production of gelatinous mass
The process during which the homogeneity of the air blister-free mass and the color are controlled
3
Weighing
The weighing process of the ingredients is carried out in accordance with the approved technological specification, in which an individual code is assigned for each of the substances, in order to ensure full traceability
4
Production of filling
A process that takes into account mixing. The detailed operating instructions define the order and method of mixing all the ingredients. The operator makes an organoleptic assessment of the mixture - color, smell, aeration.
5
Encapsulation
The operator continuously checks, confirming the compliance of the soft capsules with the technological instructions for production and specifications: temperature conditions and humidity in the production room, the weight of the whole capsules and in more detail - the weight of the shell or the mass of the batch. The thickness of the gelatin strips, the speed of encapsulation and the temperature of the injection segment, the gelatinous mass, the filling are also continuously controlled.
6
Drying
The temperature conditions and humidity in the drying tunnels and the hardness of the produced capsules are controlled
7
Polishing and sorting
At this stage, the degree of purity of the surface of the capsules after polishing is controlled and the uniformity of shape or physicochemical parameters is controlled
8
Packing
The stage during which, parameters such as: uniformity of shape, purity of the surface of capsules, physicochemical parameters are controlled.
The process of production of gelatinous mass is carried out in a mixer with a heating jacket. The raw materials are drawn through a vacuum system into the mixer, where they are mixed, dissolved and vented. The resulting gelatinous mass can be colorless or colored.
Weighing
The weighing process of the ingredients is carried out in accordance with the approved technological specification, in which an individual code is assigned for each of the substances, in order to ensure full traceability
Production of filling
We specialize in the production of oil-filled capsules. We can encapsulate pure oils, oil mixtures and single and combined combinations of fat-soluble vitamins — A, D, E, K.
Encapsulation of soft capsules
We have a soft capping machine from the renowned Technophar company. Currently we have 5 oval, 10 oval and 5 twist off formats, but at the customer's request we are able to order any matrix in a short time. Our soft capping machine is a very efficient device adapted to large production volumes.
Drying
We dry the capsules in pre-drying drums that work with the capping machine and then place them on trays in the tunnel dryer. Thanks to the two-stage drying model, we are able to precisely determine the drying moment of the capsules. We determine the end of drying by examining the hardness of the capsules with the help of a modern hardness tester.
Polishing
In the process, we polish the capsules until a smooth and shiny surface is obtained.
Sorting
The sorting process ensures uniformity of the size of the soft capsules, all capsules that do not fall within the scope of the product specification are discarded. Thanks to this process, the blister packaging process is fast and hassle-free.
Packing
Produced soft capsules can be delivered as: bulk product (BULK), in blisters, blisters and cartons, plastic jars with a label.
We have high efficiency blister lines with automatic cartoning machine, as well as automatic counting machines for packaging into jars.
Questions about services
What size capsules do you produce?
Currently we have equipment for capsules of sizes 5Oval, 10Oval, 5 Twist-off but in a relatively short time we can arm ourselves with practically any capsule size offered on the market.
Do you produce vegan/vegetarian gelatin capsules?
No. Our products are always based on gelatin of animal origin.
What is the minimum quantity of capsules we can order from you?
The minimum quantity depending on the size of the capsules is shown in the table below:
size
Minimum Quantity (pcs.)
2 oval
3 oval
4 oval
5 oval
5 twist off
7.5 oval
10 oval
12 oval
600,000
500 000
400 000
400 000
250 000
300 000
300 000
200 000
250 000
16 oblong
200 000
20 oblong
Do you encapsulate oils that we will deliver directly to you?
Yes, after laboratory and technological tests and acceptance of your oils, we are able to make such capsules.
What type of gelatin do you use to make capsules?
Depending on the customer's expectations, we can use Bio-Organic beef, pork, fish, pork gelatin.
Do you produce colored capsules?
Yes, we can produce both colorless and colored capsules in the color you expect. We can also produce bicolor capsules.
What fillings do you encapsulate?
Oil molds are our main mold for the production of soft capsules. In order to prepare more demanding forms, such as suspensions or emulsions, it is necessary to carry out a technological evaluation of the appropriate formulation, carried out on a case-by-case basis by our experts.
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