Everyone would take gelatin capsules for health benefits. They play an important role in the dosage form to hold powders or liquids. These capsules have become a familiar part of daily health.
What are gel capsules made of?
As the name says, gelatin is an important ingredient from animals. This material makes the capsule easy to swallow. Besides gelatin, other ingredients are added. They work together to improve the quality and stability. Common ingredients include
- Water. It keeps the capsule flexible and prevents it from being too hard or brittle.
- Plasticizers, such as sorbitol. They make the capsule softer and more elastic.
- Coloring agents. They are always used for an attractive appearance or to help distinguish different products.
- Preservatives or flavoring agents. They can be added based on your needs.
Together, these ingredients create a capsule shell that is strong enough to hold the drug or supplement. The gelatin shell also dissolves quickly in the stomach for fast absorption.
Benefits of gelatin capsules
Gelatin capsules have many advantages. Their smooth surface and simple shape make them more comfortable to swallow. They also make the smell and taste better. This is important for ingredients with strong or unpleasant flavors. Another benefit is their fast dissolution in the stomach. This allows the body to absorb the active substance quickly.
Gelatin capsules vs vegetarian capsules
Gelatin and vegetarian capsules have many differences. The first key one is the ingredients. Vegetarian capsules are produced from plant-based materials such as HPMC or pullulan. They are suitable for vegetarians or people who can’t eat animal products. Compared to gelatin capsules, veggie capsules are more expensive. Because the manufacturing process is more complex.
Gelatin capsules are widely accepted by most people. Vegetarian capsules provide an alternative for people with dietary or lifestyle limits. Manufacturers often decide which type to use based on the target market and customer preference.
Two categories of gelatin capsules
Hard capsules
This type consists of a body and a cap. They are usually filled with dry powders, granules, or tiny pellets. These capsules are rigid, and they maintain their shape well. Hard gelatin capsules are always used for vitamins, herbal supplements, and prescription medicines that require precise dosing.
Soft capsules
Soft gelatin capsules are integrated with a continuous shell. They could contain liquids, oils, or semi-solid substances. Softgels feature a soft and elastic shell. It allows for easy swallowing and protects sensitive ingredients, such as fish oil and fat-soluble vitamins. Different from hard capsules, soft gelatin capsules can be customized in different shapes, including oval, round, etc.
How to manufacture gelatin capsules?
Hard and soft capsules have different manufacturing processes. Here, I take the hard gelatin capsules for example.
Material preparation
At first, capsule makers need to prepare all the raw materials they need, like gelatin. Before use, each raw material needs to conduct laboratory testing for microbiological safety, heavy metals, and physical properties. Only approved batches move into production.
Gelatin mixing
Next, dry gelatin is soaked in cold purified water and heated gently in tanks. This process continues until it melts into a transparent solution. Careful control of temperature is needed. It prevents degradation of the gelatin protein.
Once the gelatin has melted into a liquid, other materials like plasticizer and color agents are added.
Capsule shell forming
In this step, rows of smooth metal pins are dipped into the liquid and then slowly come back out. A thin layer of gelatin sticks to each pin as it leaves the liquid. The thickness of the layer depends on how thick the liquid is and how long the pins stay in it.
Drying and packaging
Then, they move into a drying tunnel. Gentle air removes moisture slowly to prevent cracks. When the shells are firm and flexible, they are stripped from the pin. Capsule bodies and caps are then formed and polished.
Capsule manufacturers check for defects such as cracks, holes, or uneven color. The qualified empty capsules are finally packed well.
Four common machines used for gelatin capsules
As capsules are the most popular dosage form, they could be used with many machines. Here are some examples for capsule production and filling.
Gelatin melting and mixing tanks
These tanks are used at the beginning of capsule production. They prepare a smooth and bubble-free gelatin solution. The tanks keep the liquid at a steady temperature so it does not thicken or spoil before use.
Capsule filling machines
These machines are used to fill capsules with different products. Depending on the machine design, they can handle powders, granules, pellets, or even liquids. The capsule filling machine separates the cap and body of each capsule, fills the body with the correct amount of material, and then closes it again. Their function is to ensure each capsule has a uniform dose and safe use.
Based on automation levels, capsule fillers could be divided into three types: manual, semi-automatic, and fully automatic ones. Manual models are the cheapest, but they feature low efficiency. So they are always used for small production, like workshops. Fully automatic capsule filling equipment automates the whole process from filling to sealing. They feature the highest efficiency, but the price is also the highest. Large-volume production will prefer this type. Semi-automatic models balance the cost and efficiency. You can choose the most suitable one based on your needs.
Inspection machines
Inspection machines are used to check the quality of filled capsules. They use cameras or sensors to detect problems such as cracks. Some systems automatically reject faulty capsules, while need human help.
Polishing machines
The capsule polishing machine is designed to clean and improve the appearance of capsules. They remove any dust or excess powder from the capsule surface. This gives capsules a smooth and glossy finish that looks more attractive.
The end
Gelatin capsules are popular because of their smooth texture, easy swallowing, and versatility for different medicines. As demand continues, gelatin capsules will keep playing an important role in healthcare and nutrition.