Softgel Encapsulation Machine

A softgel encapsulation machine is a rotary die system that forms two shell ribbons, meters the fill material between them, and simultaneously shapes, fills, seals and cuts individual soft capsules.

Yes. Both normally refer to the same type of rotary die equipment. “Softgel encapsulation machine” is the more concise primary keyword, while “soft gelatin encapsulation machine” is an important synonym.

No. A softgel machine forms and seals the capsule shell during filling. A hard capsule filling machine fills pre-manufactured two-piece capsule shells with powder, granules, pellets or suitable liquids.

Suitable materials can include oils, liquid formulations, suspensions and certain semi-solid products. The formulation must be evaluated for viscosity, particle size, temperature sensitivity and compatibility with the capsule shell.

Available models range from the RGY2-15 laboratory machine to high-capacity systems with a reference output of up to 241,920 capsules per hour. Actual output depends on the capsule and process configuration.

Yes. Different capsule shapes and sizes can be produced by replacing the die rolls and corresponding format parts.

Alternative shell formulations may be possible, but compatibility must be confirmed through formulation evaluation and production trials. Heating, ribbon formation, cooling and drying conditions may differ from standard gelatin.

Drying time depends on the shell formulation, capsule size, fill material, room conditions and drying system. Selected intelligent dryer configurations reference approximately 12–16 hours, but the actual process must be validated for the product.

The equipment can be configured with sanitary materials, cleanable structures and suitable process-contact components. Final GMP compliance depends on the selected configuration, facility, documentation, operating procedures and validation performed by the manufacturer.

The price depends on the machine model, tooling, automation level, auxiliary equipment and project services. A complete quotation requires the capsule size, fill volume, formulation type and target production capacity.

Common issues include: 1) Uneven ribbon thickness, usually caused by unstable spreader box temperature, uneven feeding, or improper die gap settings (adjust spreader temperature and gel fluid flow); 2) Leaking or poor capsule sealing, often due to incorrect injection wedge temperature, improper gelatin moisture, or insufficient die pressure (fine-tune wedge temperature and center distance); 3) Sticky or distorted capsules, usually caused by poor drying temperature and humidity (optimize tumbler dryer speed and ensure environmental control standards are met).

The gelatin must have the proper viscosity and Bloom strength (typically between 150 and 250 Bloom) to ensure sufficient mechanical strength and elasticity. Water content and holding temperature during melting must also be strictly controlled; ribbons that are too thick cause slow drying, while ribbons that are too thin can easily break during encapsulation.

A standard softgel production line includes: 1) Gelatin melting system: melting tanks, preparation vessels, and vacuum degassing systems; 2) Feeding and conveying system: fill material mixing tanks, transfer pumps, and jacketed service hoppers; 3) Main machine: softgel encapsulation machine; 4) Drying system: tumble dryers, drying trays/trucks or main drying rooms; 5) Auxiliary equipment: capsule washing machines, sorting/inspection machines, and final packaging equipment.

For small-scale batches or laboratory R&D, choose a compact lab-scale or small softgel machine with smaller die rolls, lower speeds, and quick mold-change features. For large-scale industrial production, choose a high-speed, high-stability automatic softgel machine, paying close attention to its maximum hourly output, die roll speed, and cooling efficiency to ensure continuous, heavy-duty production stability.

Key maintenance steps include: 1) Cleaning and sanitation: thoroughly clean die rolls, injection wedges, spreader boxes, and all contact pipelines and pumps after each production run to prevent residue buildup, bacterial growth, or metal corrosion; 2) Lubrication management: regularly check and add food-grade lubricant to transmission parts, cams, and bearings to keep the machine running smoothly; 3) Mold protection: die rolls are high-precision, high-value components. Avoid any bumps or scratches during installation and removal, and coat them with anti-rust oil when stored in a dry place.