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Standard softgel shells are gelatin-based. We use BSE-free, Halal certified gelatin — important for export markets in the Middle East and Southeast Asia, and increasingly for domestic retail that targets Muslim consumers. Fish gelatin is available as an alternative for brands marketing specifically to Kosher or pescatarian segments.
HPMC softgel capsules use a plant-derived shell instead of animal gelatin. They're the right choice for brands targeting vegan consumers, for products marketed as plant-based, or for markets where gelatin creates a sales barrier. HPMC shells have slightly different sealing and drying properties compared to gelatin — our process accounts for this specifically.
Gelatin or HPMC is dissolved and mixed with plasticizers (glycerin, sorbitol) and any required colorants or opacifiers to form the shell mass. Temperature and viscosity are controlled precisely — shell mass that's too thick or too thin creates encapsulation defects downstream.
The oil, PEG solution, or suspension fill is prepared and tested for viscosity, fill weight target, and homogeneity before it enters the encapsulation machine. For suspensions, particle size and settling behaviour are checked.
Two ribbons of shell mass are fed onto rotating dies that stamp out capsule halves, fill them simultaneously, and seal them — all in a single continuous operation. Fill weight accuracy is monitored continuously during the run. Leakers are rejected in-line.
Freshly encapsulated softgels have high moisture content and soft shells. They go through a controlled drying process — tumble dryers first, then tray drying — to reach the correct moisture and hardness targets. Rushing this stage causes shell deformation and reduced shelf life. We don't.
Weight variation, shell thickness, seam integrity, leaker testing, disintegration, assay — all tested on representative samples from the batch. Certificate of Analysis issued after QC sign-off. No batch dispatched without it.
Finished, dried, QC-cleared softgels are counted and packed into your branded bottles, blisters, or bulk containers depending on your distribution format. Dispatched PAN India with batch documentation and COA.
| Fill Category | Examples | Notes |
|---|---|---|
| Fixed Oils | Fish oil, flaxseed oil, evening primrose oil, vitamin E oil | Most common nutraceutical softgel fill — well-characterised encapsulation behaviour |
| Omega-3 Concentrates | EPA/DHA concentrates (500mg, 1000mg, 1200mg) | Require nitrogen flushing and antioxidant inclusion to prevent oxidation |
| PEG-based Solutions | Pharmaceutical actives dissolved in PEG 400/600 | Used for specific pharma applications where oil-solubility is limited |
| Suspensions | Actives suspended in oil or PEG vehicle | Particle size control and suspension stability critical — requires specific process parameters |
| Liquid Vitamins | Vitamin D3 in oil, vitamin K2, CoQ10 in MCT oil | Concentration and fill weight calibrated for label claim accuracy |
Not every facility actually runs both. We do. Halal certification is current and verifiable. HPMC shells require different drying parameters — our production team has the experience to run them correctly, not just theoretically.
Encapsulation and branded packaging happen at the same facility. No handoff between manufacturing and packaging contractors. Your finished, branded, QC-cleared softgels dispatch from one location with full traceability.
Omega-3s and certain other oil fills degrade quickly on oxygen exposure. We use nitrogen flushing during encapsulation and for headspace in packaging where the formulation requires it — standard practice for quality fish oil manufacturing, often skipped elsewhere.
Outsourcing QC testing to third-party labs adds time and reduces batch-to-batch feedback speed. Our in-house laboratory runs the full testing panel — peroxide value, assay, moisture, microbials — so QC clearance happens faster and problems are caught before they compound.
Rotary die machines deliver better fill weight consistency than alternative encapsulation methods. For high-potency fills where dosage precision matters, this isn't a minor detail.
Small first-order clients get the same manufacturing standard as large recurring ones. GMP applies to the process, not the batch size. COA issued per batch, automatically.
| Test Parameter | What It Confirms |
|---|---|
| Fill Weight Variation | Dosage accuracy — each capsule delivers what the label claims |
| Shell Thickness | Consistent shell integrity across the batch |
| Seam & Leaker Test | No fill seeping through the seal — a critical visual and pressure test |
| Disintegration Test | Shell dissolves within the required time for bioavailability |
| Moisture Content | Shell hardness and shelf stability — over-dried or under-dried shells both fail |
| Assay (Potency) | Active ingredient content matches label claim within acceptable variation limits |
| Oxidation / Peroxide Value | For oil-based fills — confirms fill material hasn't oxidized during production |
| Microbial Limits | Bioburden within acceptable limits for the product category |
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