Contract manufacturing of Soft Capsules softgel
Softgel - What is this?
Capsule softgel is an oral form of administration of a drug or supplement, consisting of a soft gelatin or alternative polymer shell surrounding a liquid content, produced by the rotary matrix encapsulation method, which ensures precise dosing and hermetic closure.
Capsule type softgel They are characterized by ease of swallowing, high bioavailability of active substances, storage stability and the possibility of using plant materials, which makes them a popular choice in the pharmaceutical industry and the production of dietary supplements.
Capsule Production Softgel
Our wide range of products includes capsules softgel, tailored to various needs – from vitamins to active CBD oils. We implement contract manufacturing of capsules softgel for the pharmaceutical, cosmetics (twist-off) and dietary supplements industries, offering solutions of the highest quality quality.
As experienced capsule manufacturer softgel, we provide flexibility and the ability to individually adjust the formula, size, and type of filling. Our contract capsule production softgel allows for quick implementation times and cooperation on favorable terms.
The satisfaction of our customers confirms our effectiveness – since the beginning of our operations, we have not recorded a single complaint! By choosing our contract manufacturing of capsules softgel, you focus on reliability, quality and experience.
CAPSULE PRODUCTION SOFTGEL STEP BY STEP
1. Composition and preparation of the gelatin mass
The basis of each capsules softgel is a gelatin mass consisting of:
pharmaceutical gelatin (type A or B),
plasticizer (glycerol, sorbitol),
water.
Additionally, we use safe dyes, opacifiers (e.g., iron oxides), and—optionally—preservatives. The ingredients are heated and mixed in a special mixer with a vacuum system, which allows for a homogeneous, bubble-free mass. This ensures that each capsule softgel is smooth and durable.
2. Modern encapsulation method softgel
Under contract capsule production softgel We use the most efficient rotary die method, which enables:
continuous capsule formation and filling,
precise dosing of the feed (oil, emulsion, suspension),
tight connection of the halves of the gelatin casing.
The process takes place in an automated encapsulation machine, where two ribbons of gelatin enclose a portion of the liquid feed and are then sealed under pressure and heat. Each capsule softgel leaves the device ready, tightly closed
3. Quality control in capsule production softgel
High quality capsule production softgel is maintained thanks to full control of parameters:
thickness of the gelatin ribbon,
mass and charge temperature,
weight of each capsule (total, shell and fill).
All data is monitored by PLC systems, and any deviations from the norm are immediately reported. Modern solutions allow for high uniformity and low error rates.
4. Drying and stabilizing the capsules softgel
Once formed, the capsules are still moist and soft. They harden in two stages:
Pre-drying – in rotary tumble dryers with dry air blowing.
Drying – on perforated trays in climatic chambers (20–25°C, humidity 20–30%).
This allows the capsules to achieve optimal moisture content (6–8%) and durability. Drying time and parameters are individually adjusted to the capsule's composition.
5. Polishing, sorting and packaging of capsules softgel
Finally, the capsules undergo a series of finishing operations:
polishing (mechanical or air),
sorting (automatic inspection systems eliminate defective items),
packing (blisters, bottles or bulk packaging).
The entire process takes place in air-conditioned rooms, preventing moisture reabsorption. Capsules can also be printed or laser-marked.
Contract manufacturer of capsules softgel - IOC
Experience and modernity in capsule production softgel – get to know IOC
Company IOC it's both capsule manufacturer softgel, as well as hard capsule manufacturer, which has been providing the highest quality solutions tailored to the needs of customers in the dietary supplements and pharmaceutical sectors for over 15 years.
We encourage you to contact – we will prepare a quick quote and together we will plan the implementation of your project within contract capsule production softgel.
A team of experts and an innovative approach
Our team consists of an interdisciplinary team of specialists – pharmacists, biotechnologists, chemists, and physicists – who develop unique formulas and technologies. Collaboration with scientific institutions and the implementation of solutions supported by scientific research allow us to create products with proven effectiveness.
We have technologies and ingredients available exclusively in our offer. capsules softgel is a combination of innovation, quality, and safety. If you are looking for a partner who will comprehensively implement your project – contract production capsules softgel z IOC is the right choice. Join the ranks of our satisfied customers and introduce market supplement of the highest standard.
Capsules softgel – production from IOC
W IOC we specialize in implementing projects including capsule production softgel on behalf of companies from the dietary supplements and pharmaceutical products industry.
- Advanced technological facilities: As a modern capsule manufacturer softgel, we use innovative encapsulating devices, dryers and polishers, as well as automatic production lines blisteringThis ensures high efficiency, repeatability, and precision in every batch.
- Individual approach to the client: Our contract manufacturing of capsules softgel is fully flexible – we offer a variety of capsule sizes and colors, numerous filling options, and diverse packaging options. We tailor the product to the specific vision of the client and their target group.
- Quality and compliance with standards: W IOC Quality and safety are our top priorities. We operate in accordance with international GMP and ISO standards, guaranteeing the highest quality of every product we produce. capsules softgel.
- Experience and innovation: We have many years of experience in the industry and specialist knowledge in the field capsule production softgelWe monitor technological developments to offer solutions that align with the latest trends and market expectations.
Working with IOC, you can focus on building your brand and marketing activities - we will take care of the entire process, which includes contract capsule production softgel, guaranteeing the highest quality and punctuality.
contract capsule production softgel - quality control
W IOC each stage of production is rigorously controlled to ensure the highest quality of products. Our plants meet a number of international standards and have certificates guaranteeing the highest industry standards:
- ISO 22000 – Food Safety Management System.
- ISO 9001 – Quality Management System.
- ISO 22716 – Good Manufacturing Practices (GMP) for cosmetics.
- GMP (Good Manufacturing Practice) – Good Manufacturing Practices.
- HACCP – Hazard Analysis and Critical Control Points.
- GHP (Good Hygiene Practice) – Good Hygiene Practices.
- CSR (Corporate Social Responsibility) – Corporate Social Responsibility.
In addition, we use the philosophy Lean Manufacturing, 5S and Kaizen Philosophy for continuous optimization of production processes and ensuring the highest efficiency.
Below are the company's current certificates IOC.
Modern solutions in capsule production softgel used by IOC
As experienced capsule manufacturer softgel, IOC sp. z o. o. implements innovative technological solutions that enable the creation of effective and advanced dietary supplements. Our activities combine a scientific approach with industrial practice, ensuring that each production batch meets the highest quality standards.
Below is an overview of the technologies used in capsule production softgel, taking into account their key advantages for both consumers and producers.
An innovative approach to contract capsule manufacturing softgel
As part of the services we offer contract manufacturing of capsules softgel, we utilize technologies that increase the effectiveness and quality of the final product. We use, among others, liposomal technology and nano-micellization, which improve the absorption of active ingredients. Supercritical CO₂ extraction allows for the production of pure raw materials for the production of dietary supplements no chemicals, and microencapsulation ensures controlled release of the substance.
Thanks to this, each capsule softgel produced by IOC meets the highest quality standards. Our modern capsule production softgel guarantees effectiveness, durability and safety, both for customers and end consumers.
| Technology | Description | Benefits for the Consumer | Benefits for the Producer |
|---|---|---|---|
| Liposomal Technology | Surrounding the active ingredients with a lipid layer. | Increased bioavailability and stability of ingredients. | Less loss of ingredients, which increases production efficiency. |
| Nano-Micellization | Transforming ingredients into microscopic particles. | Better absorption of active ingredients by the body. | Higher product quality and efficiency. |
| Emulsification | Creating emulsions combining fatty and water components. | Stable and effective supplement formulas. | Possibility to create more complex products. |
| Supercritical CO2 Extraction | Obtaining natural oils without chemicals. | Cleaner and better quality products. | Increased process quality and cleanliness. |
| Microencapsulation | Surrounding active ingredients with microscopic particles. | Controlled release of ingredients. | Improved production stability and efficiency. |
| Sustainable and Ecological Technologies | Use of raw materials from ecological sources. | Minimizing environmental impact. | Building a positive brand image. |
| Low Temperature Mixing and Emulsion Technology | Combining ingredients at lower temperatures. | Preservation of biological properties. | Optimization of production processes. |
Knowledge Compendium: Contract Manufacturing Softgel
Answers to technical, logistical and quality questions regarding cooperation with IOC.
What are capsules softgel and why is it worth choosing the Rotary Die method?
Capsule softgel is a hermetic drug and supplement delivery system consisting of a flexible shell (gelatin or vegan) and a liquid filler. The method we use Rotary Die ensure:
- Dosing precision: The margin of error of the scale is minimal.
- Hermeticity: The shell is sealed at the time of dispensing, which protects sensitive oils (e.g. Omega-3) from oxidation.
- Bioavailability: The liquid form is absorbed faster than hard tablets.
What is the minimum order (MOQ) and what does it result from?
Standard minimum production (MOQ) totals 300 capsules for one process (which translates into, for example, 5000 packages of 60 pieces each). This is the technical threshold necessary to:
- Correct calibration of rotary machines.
- Preparation of the appropriate amount of gelatin mass (melting and deaeration processes require a specific batch volume).
- Achieving economic profitability for the customer while maintaining GMP standards.
How long does the production process (Lead Time) and drying stages take?
The complete implementation process of a new product usually takes from 3 to 6 monthsThe key step that cannot be rushed without sacrificing quality is two-stage drying:
- Stage 1: Drying in rotating drums (removal of surface water).
- Stage 2: Drying on trays in climatic chambers (20–25°C, humidity 20–30%) to obtain the appropriate hardness of the shell.
What quality certificates does the production plant have? IOC?
Our plant meets stringent pharmaceutical and food standards, as confirmed by the following certificates:
- GMP (Good Manufacturing Practice): For both supplements and cosmetics (ISO 22716).
- ISO 22000 & HACCP: The highest standard of food safety.
- ISO 9001: Quality management system.
- CSR: Corporate Social Responsibility Certificate.
What innovative technologies (Liposomes, Nano) do you offer?
To increase the market advantage of your product, we use:
- Liposomal technology: Encapsulation of the active substance in a lipid envelope for maximum absorption.
- Nano-micellization: Fragmentation of particles to nano size, which allows for faster absorption.
- Supercritical CO₂ extraction: Obtaining ultra-pure oils without the use of chemical solvents.
- Microencapsulation: Controlled release of ingredients.
What is the production process like step by step?
- Preparation of the mass: Melting the gelatin and mixing in a vacuum (eliminating air bubbles).
- Encapsulation: Forming and filling on rotary machines.
- Drying and stabilization: Moisture removal to a level of 6-8%.
- Finish: Polishing, optical sorting (elimination of defects) and packaging.
What types of fillings can be used in softgel?
This technology is ideal for:
- Oils (fish, vegetable, CBD).
- Fat-soluble vitamins (A, D3, E, K2).
- Suspensions (thick pastes, plant extracts in oil).
- Substances sensitive to light and oxygen (e.g. coenzyme Q10, lecithin).
What are the packaging options for the finished product?
We offer full clothing (Private Label):
- Blistering: (PVC/Alu, Alu/Alu) – pharmacy standard.
- Jars and bottles: Glass or PET with labels.
- Doypacki: Modern foil packaging.
- Bulk packaging for customers with their own packaging facilities.
What does quality control (QC) look like?
Each batch undergoes rigorous testing including:
- Verification of raw material purity (heavy metals, microbiology).
- In-line process control (web thickness, capsule weight, tightness).
- Laboratory testing of the final product before release to the market.
Is it possible to personalize the shape and color?
Yes. We offer standard shapes (Oval, Oblong, Round) in various sizes. The shell can be transparent, dyed any color (including natural dyes), or pearlescent. We can also print a design (e.g., a logo) directly on the capsule.
Do you help with registration (GIS) and export?
Yes, our legal department supports the supplement's notification process with the Chief Sanitary Inspectorate (GIS) in Poland. We also prepare the documentation necessary for export to EU and non-EU markets (Certificates of Analysis, Specifications).
What is AI technology verification?
We offer an initial, anonymous review of your supplement idea using our AI assistant. This allows you to quickly assess its technological potential before formally contacting our sales department.