Manufacturing of Soft Gelatin Capsule Complete Process & Companies List – Softgel capsules are one of the most popular drug delivery systems preferred by many consumers and manufacturers due to their ease of administration. These dosage forms offer many advantages and undergo a detailed manufacturing process. Following this blog we are going to discuss the Manufacturing of Soft Gelatin Capsule Complete Process & Companies List.
Soft gelatin capsules are a form of capsules that usually enclose liquid or powder medication inside their shells. These capsules are usually hermetically one-piece capsules and are made from a flexible, plasticized gelatin film. These capsules are highly demanded in the pharmaceutical industry due to their many potential benefits over hard gelatin capsules or tablets.
Compared to hard gelatin capsules, soft gelatin capsules are thicker and require additional ingredients such as glycerin to obtain their soft texture. These capsule form is also seen to dissolve quickly and are very easy to use and swallow making them a preferred choice among a huge population.
According to allied market research, the Global softshell capsule market size was estimated to be US$ 4.4 billion in 2021 and is now anticipated to reach a value of US$ 7.5 billion by the year 2031 at a CAGR of 5.4% during the forecast period.
Manufacturing of Soft Gelatin Capsule Complete Process
Now, let’s take a look at the Manufacturing of Soft Gelatin Capsule Complete Process to under the whole process in depth. The process is usually divided into 6 major steps.
Gelatin Preparation
Fill Material Preparation
Encapsulation
Drying
Inspection and Sorting
Cleaning and Polishing
Step 1. Gelatin Preparation
This process involves the preparation of a soft gel shell which usually contains medicinal material. This shell is usually made from a mixture of animal- or plant-based gelatin, a plasticizer, water, color, and flavor. Some ingredients can be avoided or added as per production requirements.
All the material is added to the gelatin melting tank. During this process, the tank mixes all the ingredients and gelatin in warm water by keeping the mixture at the proper temperature until a gel mass is formed.
Step 2. Fill Material Preparation
Fill material comes in a variety of forms such as liquids, oils, suspensions, or semi-solids, and is defined as the medication enclosed by the soft shell. In this process, fill materials are mixed and milled in a processing tank to form a fill mass. Then they pass through the vacuum to remove any air bubbles if necessary.
The liquid fills and gelatin are then transferred to a service tank ready for the encapsulation process.
Step 3. Encapsulation
It is a very complex step and is divided into further sub-steps.
Gel mass is pumped into the machine and two thin ribbons of gelatin are formed.
These ribbons then pass over a series of rollers and are constantly fed between two rotating die cylinders to determine the shape and size of the capsules.
After this filling injector comes into play, where the fill material is encapsulated by measuring and dispensing in the most appropriate volume.
With the rotation of the die assembly, capsule halves are then sealed through heat and pressure and are then ejected.
Step 4. Drying
In this process, the prepared soft gel capsules undergo a drying process in a tumbler dryer which focuses on removing any excess moisture on the soft gel capsules using lint-free towels and forced air.
Step 5. Inspection and Sorting
It is one of the most important steps where the soft gel capsule is transferred to the inspection station for quality control. Even while working in a state-of-the-art facility or with highly sophisticated machines, there is always a chance of error or defect. So, these quality procedures help to prevent any undersized oversized, deformed, or leaking soft gel capsules.
This is usually done by automatically inspecting machines that sort out defects based on color, shape, thickness, or diameter requirements.
Step 6. Cleaning and Polishing
After sorting out the good quality capsules, the soft gel capsules then pass through the polishing machine to remove any oil residue or debris from the surface. You can also choose a wide range of printing applications, such as product names, brand logos, and feature pictures.
The List of Top 10 Pharma Companies Involved with the Manufacturing of Softgel Capsules
1. Sigma Softgel & Formulation –
Sigma Softgel & Formulation has become one of the most respected names among the Top 10 Pharma Companies Involved with the Manufacturing of Softgel Capsules. Through constant research, new formulation development, and product innovations, they are committed to delivering better health through superior products with a desire to provide opportunities for a better life.
Address – 7th Floor, Mid Town Business Park, Peer Muchalla, Near Sector-20, Panchkula, India, Pin Code:- 140603
2. Nava Healthcare –
Nava Healthcare is one of the fastest-growing pharmaceutical companies in India, well-known for its high-quality medication and services. Through a decade of experience, this WHO-GMP-certified company is highly driven by continuous Research and Development for the development of new products in various formulations. Their soft gelatin capsule range covers wide therapeutic segments, Personnel care & OTC solutions.
Monnark Biocare is a trusted name in the pharma industry due to its exceptional range of soft gel capsules. This leading ISO-certified Pharma Company handles a wide product portfolio of 2000+ DCGI-approved products in various dosage forms like tablets, soft gelatin capsules, dry syrups, injections, ointments, and others. With advancements in technology and state of the art facility, this company has specialized in the manufacturing of a wide range of medicines efficiently.
Macleods Pharmaceuticals was established in 1989, and since then they have been involved in in development, manufacturing, and marketing of a wide range of dosage forms across several major therapeutic segments such as anti-infectives, cardiovascular, anti-diabetic, dermatology, and hormone treatment. Their operation are supported by 8 state of the art manufacturing facilities approved by WHO, FDA, and MHRA.
Address – 304, Atlanta Arcade, Marol Church Road, Andheri, Mumbai, Maharashtra, Pin Code:- 400059
5. Jes Pharmacia Private Ltd –
Jes Pharmacia is an energetic pharma manufacturing company proficient in handling a wide collection of Analgesics, Anti Infective, Critical Care Antibiotics, Nutritional Products, Gastric, Anti Ulcerant, Haematinics Protein Powders, etc. Through their never compromise on quality all of their product range adheres to necessary quality standards.
MMC Pharmaceutical has been an asset of quality through its focus on Neurology, Respiratory, Gynecology & infertility therapy areas. Their quality pharmaceutical factories have been one of the major pillars behind their success. During their production process, they make sure to maintain 100% compliance with all legal, statutory, regulatory, and other specific requirements.
Being a full-service manufacturer of soft-gelatin capsules, Alder Biochem is known to deliver high-quality formulations to over PAN India. With a production capacity of 1 billion capsules annually, they operate in best-class machinery, and modern labs running under the guidance of experienced professionals. In addition to this, their state-of-the-art facility is equipped with the latest IOT-based system enabling faster, error-free production.
Novolilly Pharmaceutical is a multi-faceted healthcare company with proficient state-of-the-art manufacturing facilities, and R&D centers working as per International Standards. All of their product range covering segments like Antibiotics, Anti-infective, Pediatric, Health Supplements, Cardiology, Diabetology, Gynecology, etc are highly appreciated on a global scale.
Since its inception, Ernst Pharmacia has been nurturing health through the mnaufactuing of high-quality and cost-effective medications making them one of India’s fastest and finest-growing pharmaceutical companies. Through a versatile range of soft gelatin capsules, they have been dedicated to serving clients all across India helping them to lead a healthier and happier life.
Akums Drugs and Pharmaceutical delivers a comprehensive range of high-quality soft gel capsules in various segments. They are backed by over 15 manufacturing facilities and a dedicated DSIR-approved R&D center making them an established name among the other manufacturers. This company has a robust production capacity of 47888.8 million oral solids per year including soft gel capsules, vegetarian capsules, hard gelatin capsules, and many others.
We hope we were able to resolve all your doubts regarding the Manufacturing of Soft Gelatin Capsule Complete Process & Companies List. Softgel capsules are a modern way of drug delivery and have become a highly demanded dosage form due to their immense benefits.
FAQs concerning the “Manufacturing of Soft Gelatin Capsule Complete Process & Companies List “
Question 1. what are the advantages of soft gel capsules over other dosage forms?
Answer 1. Soft gelatin capsules offer advantages that make them a preferred choice among consumers and manufacturers.
Improved bioavailability
Higher stability
Comes in a variety of colours
Easy to swallow
Help mask the bitter taste and unpleasant odor of medications
Easily dissolvable
Proficient in encapsulating liquid insoluble, and powdered drug
Question 2. How much time does a soft-gel capsule take to dissolve?
Answer 2. Usually, Softgels dissolve within 20 to 30 minutes in our stomachs. This process involves contact of the shell with water, the shell will take up water and start to swell resulting in complete dissolution.
Question 3. Are soft gel capsules better than tablets?
Answer 3. Yes, capsules are much better as they are easier to swallow, absorbed faster, and mask the bitter taste of a potent drug, unlike tablets.
Question 4. What category of medications are most suitable for gelatin capsules?
Answer 4. Softgel capsules are quite suited for liquid or semi-solid fillings and can be used in a wide range of nutritional supplements, such as omega-3 fish oils.
