Custom Softgel Manufacturing
Premium softgels-gelatin or plant-based-optimized for fill stability, leak resistance, and shelf-life. Built for speed, quality, and scale insideFDA-, cGMP-, and NSF-certified facilities.
Softgels Engineered for Stability and Scale
We match shell chemistry, plasticizer ratios, and fill systems to your actives-then validate weight, seal integrity, and oxidation so production mirrors pilot.
Fill System Mastery
Triglyceride oils, MCT, omega concentrates, oil-suspended powders, or microemulsions tuned for viscosity, homogeneity, and active protection.
Shell & Seal Integrity
Gelatin or starch/HPMC systems balanced for strength and disintegration; banding and leak testing dialed in to reduce rejects.
Retail & Marketplace Ready
Documentation, COAs, and label logic aligned to FDA and channel standards to keep onboarding smooth and listings live.
Shell Options
- Gelatin (bovine, fish)
- Plant-based starch/HPMC
- Plasticizer systems tuned for climate
- Opaque, transparent, or two-tone colors
Fill Types
- Oils & omega concentrates
- Oil-suspended actives
- Emulsions & self-emulsifying systems
- Odor & taste masking strategies
Quality & Stability
- Fill weight & content uniformity
- Leak, seal, and rupture force checks
- Peroxide/anisidine (oils) & TOTOX trends
- Accelerated stability guidance
Presentation & Packaging
- Laser/inkjet printing & branding
- HDPE/PET bottles & blisters
- Nitrogen flush & oxygen barriers
- Retail cartons & kitting
Our Softgel Workflow
A five-stage path that safeguards stability, seal integrity, and compliance while keeping timelines tight.
Brief & Targets
Claims, audience, dosage, target volume/size, and climate/shipping constraints mapped to a manufacturable plan.
Architecture
Shell system, plasticizer ratios, and fill type selected; oxidation and moisture risks addressed early.
Prototype
Lab batches with criteria for viscosity, fill weight, seal strength, disintegration, and visual appearance.
Pilot & Verification
Line trial confirms throughput, reject/leak rates, TOTOX trends for oils, and packaging fit; label logic validated.
Release
Final spec, COAs, master label, and documentation for repeatable scale and channel onboarding.
Quality, Documented
Every prototype and lot is traceable. In-process checks keep seals tight, oxygen low, and labels defensible.
- Fill weight & content uniformity
- Leak, seal, and rupture force testing
- Peroxide, anisidine, and TOTOX (oils)
- Microbial, heavy metals & identity/potency
Softgel Specialties
Differentiate with shape, finish, and targeted release-without sacrificing throughput or compliance.
Shapes & Branding
- Oval, oblong, round & specialty
- Custom colors & two-tone shells
- Laser/inkjet printing & anti-counterfeit
- Polish & visual consistency
Performance & Protection
- Enteric & targeted release options
- Nitrogen purging & oxygen barriers
- Light- and moisture-protective packaging
- Odor mitigation & flavor systems
Certifications & Preferences
- Halal/Kosher options by facility
- Allergen & gluten-free strategies
- Non-GMO & clean-label excipients
- Climate-aware shell systems
Softgel FAQs
Answers on shells, leak control, oxidation, and timelines.
Do you offer plant-based softgels?
Yes. We support starch/HPMC systems for plant-based softgels and will recommend a shell matched to your fill and climate profile.
How do you prevent leaks and deformation?
We tune shell/plasticizer ratios, drying conditions, and banding parameters, then validate with leak and rupture force testing.
How is oxidation controlled for oil-based fills?
Nitrogen handling, low-oxygen packaging, and antioxidant strategies are paired with PV/AV monitoring to keep TOTOX within targets.
What are typical lead times and MOQs?
Lead times depend on shell type, color/printing, and fill complexity. We support flexible MOQs and prioritize the fastest compliant path to launch.
