Softgel Manufacturing
We plan fill formulation, shell preparation, encapsulation, controlled drying and packaging together for your softgel project. Evaluating shell and fill compatibility alongside the manufacturing process supports informed decisions when moving to commercial scale.
Annual Capacity
1.05 billion softgels per year, based on three-shift operations.
Fill Formulation
Active ingredients, carrier systems, fill viscosity, physical stability and shell compatibility are evaluated for the intended product.
Softgel Shell and Product Design
Shell composition, shape, size, color and performance requirements are assessed for each project. We can use bovine-derived or fish-derived gelatin in softgel manufacturing. The gelatin source is evaluated according to customer preference, formulation and product requirements.
Chewable Softgels
We also develop and manufacture suitable chewable softgel concepts with specific texture and use requirements.
Manufacturing Process
- Fill preparation
- shell preparation
- softgel encapsulation
- tumble drying and drying-room processing
- relevant quality checks
- filling and packaging
Coating Options
Enteric coating can be applied to softgels after manufacturing and drying. At Samti Nutraceuticals, every enteric coating run is followed by checks using a dissolution test apparatus to evaluate capsule acid resistance and opening behavior under conditions representing gastric acidity.
In-House Packaging
Bottles, jars and other technically suitable packaging options are evaluated for the formulation and product. Filling, labeling, coding and secondary packaging are performed in-house.
Traceability
Raw-material lots, production batches and relevant process records are linked through ERP. Explore our quality and traceability approach.
Frequently Asked Questions
Can you manufacture plant-based gelatin-free softgels?
Technically, yes. Gelatin-free softgels can be manufactured using plant-based polymers. However, these formulations require different process parameters and machine settings from standard gelatin-based production. Adapting the production system and stabilizing the process can take considerable time, so this is not a preferred priority within our current production planning. Requests are assessed individually for technical suitability and production conditions.
Do you manufacture chewable softgels?
Yes. Chewable softgel projects are evaluated for formulation, shell characteristics and manufacturing feasibility.
Can capsule size and color be customized?
Suitable shapes, sizes and colors may be evaluated according to tooling, materials and project requirements.
Minimum order quantity and production timing are assessed for each project according to formulation, packaging and material availability. See Frequently Asked Questions for general information.