Soft Capsule Production Softgel w IOC - FAQ
What does the capsule ordering and production process look like? softgel?
Soft Capsule Ordering and Production Process softgel w IOC z o. o. is carefully constructed to ensure the highest quality standards and satisfaction of our customers. It all starts with an initial consultation, during which we carefully discuss the client's needs and expectations, including product specifications, required quantities and preferred delivery dates.
After defining the requirements, our specialists start creating a personalized formula and capsule design, always taking into account the client's specific needs and goals. In the next step, we begin the production stage, using advanced technologies and observing Good Manufacturing Practice (GMP) standards, which guarantees that each series of products meets the highest quality standards.
Each batch of capsules is subjected to rigorous quality controls, including composition and purity tests, to ensure that the final product is free from any undesirable substances and contaminants. After quality control is completed, the capsules are properly packed and prepared for shipment to the customer.
Throughout the entire process, from initial consultations to finalization of the order, our clients can count on constant contact and support from our team. Thanks to this, we ensure not only trouble-free order fulfillment, but also complete satisfaction with our services and products.
What are your minimum order quantities (MOQ) for capsules softgel?
Our minimum order quantities (MOQ) for soft capsules softgel are 300 thousand capsules. This quantity allows for the creation of, for example, 5 thousand packages, with 60 capsules in each. For orders involving more complex technologies or formulations, the minimum order quantity may be higher. Specific requirements, such as capsules with suspensions or colored shells, may require additional technological tests to ensure the highest quality and compliance with the product specifications.
Do you offer support in designing formulas and capsule packaging? softgel?
Absolutely, v IOC sp. z o. o. we provide comprehensive support in the field of formula design and packaging of soft capsules softgel. As specialists in contract manufacturing and brand building, we offer a comprehensive range of services – from formulating dietary supplements, through their production, to branding and product registration processes. We have the necessary resources and know-how to provide our clients with tailor-made solutions that will distinguish their products on the market and allow them to effectively build their own brand. Our experience and expertise are fully adapted to the requirements of clients looking for products of the highest quality and uniqueness.
Can you provide large-scale production of soft-gel capsules?
Definitely, v IOC sp. z o. o. we have production capacities that allow us to produce capsules softgel not only on a smaller scale, but also on a large scale. We have extensive experience and appropriate technical and human resources that enable us to effectively adapt to the diverse needs and expectations of our customers, regardless of the size of the order. We offer a full range of services, from the design stage of the formula and packaging to final production, ensuring that each product is of the highest quality and is completely unique.
What are the typical lead times for orders for soft-gel capsules?
We understand that lead time is an important aspect when planning orders. In the case of soft capsule production softgel, typical lead times range from 3 to 6 months, which is due to our commitment to delivering the highest quality products and meeting the specific needs of each customer. We encourage you to contact us to discuss details and possible lead times before finalizing your order, so that we can best accommodate your schedule. It is worth emphasizing that lead times are subject to change, but we make every effort to ensure on-time deliveries.
Can I place a trial order before a larger production batch?
Of course, v International Organic Company sp. z o. o. we provide the possibility of placing a trial order before starting a larger production series. This approach allows for conducting technological tests aimed at ensuring that the final product meets all quality expectations. As part of the trial order, we deliver a test batch of soft capsules softgel, which gives our customers the opportunity to evaluate the product and, if necessary, make any necessary modifications to the manufacturing process before full-scale production begins.
Do you offer advice on market trends and innovations in the soft-gel industry?
We offer advice on current market trends and innovations in the soft-gel industry. As experts in contract manufacturing and building premium brands, International Organic Company sp. z o. o. has a wealth of knowledge and experience that allows us to constantly monitor the latest development trends and innovative solutions in the industry. Our team of specialists provides comprehensive support to assist our clients in creating products that not only set new standards in the industry, but also perfectly match current consumer preferences and expectations. We offer assistance not only in the field of technology and production, but also in marketing strategies and effective product positioning, which is crucial for building a strong market position in the cosmetics and dietary supplements segment.
To which countries can we export dietary supplements produced in? IOC?
International Organic Company sp. z o. o., thanks to its experience and extensive infrastructure, is able to export dietary supplements to many countries around the world, including European Union member states and selected non-European markets. Our business is based on a solid understanding of international standards and regulations regarding dietary supplements, which allows us to adapt our products to the specific legal and quality requirements applicable in individual countries. By working closely with local partners and regulatory institutions, we ensure that all the supplements we produce meet the necessary criteria, enabling their seamless export and distribution to selected markets.
What are soft-gel capsules and what are they used for?
Soft capsules soft-gel is a special type of capsule that has a soft, flexible shell, usually made of gelatin, water, and plasticizers. They are designed to encapsulate and protect a variety of substances, including oils, vitamins, minerals, and other active ingredients. These capsules are very popular in the dietary supplement and pharmaceutical industries because they allow for easy and effective delivery of active ingredients in liquid form to the body. Additionally, they are easier to swallow than traditional tablets and can be tailored to suit different needs, for example by changing color or adding flavors to increase consumer appeal.
What ingredients can be placed in capsules softgel?
Soft capsules softgel od IOC sp. z o. o. are characterized by extraordinary flexibility in terms of the content of ingredients, which makes them exceptionally versatile. Among the most sought-after ingredients are various oils, including fish oils, which are a valuable source of omega-3 acids, as well as vegetable oils such as linseed oil or hemp seed oil, known for their beneficial health properties. We do not limit ourselves to oils - in our capsules softgel may also include vitamins, minerals, plant extracts and other active ingredients used in both dietary supplements and pharmaceutical products. By using the latest technologies, we are able to precisely match the composition of our capsules to the individual needs of our customers, offering solutions tailored to the latest trends and research results in the health and wellness sector.
Czy IOC Ltd. offers the possibility of producing capsules with a colored shell?
Yes, v IOC sp. z o. o. we have the option of creating soft capsules softgel with a shell in various colors to perfectly match the expectations of our customers. Using natural and health-safe dyes, we can supply capsules in a wide range of colors, which significantly increases their aesthetic value and helps the product stand out from the competition. The ability to personalize the color of the shell is a key element for brands striving to emphasize their uniqueness and wanting to emphasize the characteristic values of their product. We ensure that our production processes are adapted to the highest quality standards, thanks to which each series of capsules is not only pleasing to the eye, but also meets all safety and efficiency criteria.
What makes it stand out? IOC sp. z o. o. as a capsule manufacturer softgel?
IOC sp. z o. o. sets standards as a manufacturer of soft capsules softgel, focusing on innovation, consistent quality and a focused, individual approach to each of our clients. In our work, we use modern production technologies that allow us to create soft capsules softgel of the highest quality, containing various active ingredients. The entire production process is carried out under rigorous quality and safety control, which guarantees that each product delivery complies with the highest standards in the industry. What's more, we offer our clients a wide range of personalization options, including the option of coloring the capsule shell and adjusting the composition of active substances, which allows the creation of unique products perfectly tailored to individual requirements. Our passion for research and development and constant pursuit of excellence allows us not only to follow current market trends, but also actively shape the future of the soft capsule industry softgel, maintaining the leadership position.
What are the main advantages of soft-gel capsules produced by your company?
Key Benefits of Softgels softgel produced by IOC sp. z o. o. focus on their unparalleled quality, precision of workmanship and efficiency in delivering active ingredients. Our capsules are distinguished by their exceptional bioavailability, which means that the active substances contained in them are effectively and quickly absorbed by the body. Their soft, flexible structure makes it easy to swallow, which is especially important for people who have difficulty swallowing traditional tablets. The range of personalization options is wide - from size, through shape, to capsule colors - which allows for adjustment to the specific needs and preferences of our customers. We also have the ability to enclose various ingredients in capsules, from oils, through vitamins, to more specialized substances. Thanks to our strict quality control procedures and compliance with the latest industry standards, each batch of capsules softgel od IOC sp. z o. o. guarantees the highest level of quality.
Can you produce soft-gel capsules with suspension?
Absolutely, v IOC sp. z o. o. we have the ability to create soft capsules softgel with suspension content. This advanced production option enables encapsulation of active substances in the form of a suspension, which is crucial for those ingredients that are not suitable for encapsulation in a purely liquid or powder state. The use of suspensions enables precise delivery of specific doses of active substances and can also contribute to increased stability and bioavailability of some compounds. Our research and development team works closely with customers to create personalized formulas that perfectly meet their unique needs and expectations. Thanks to the use of modern technologies in our production processes, we are able to efficiently fulfill orders for capsules softgel containing suspensions, while maintaining the highest quality and safety standards.
What are the different types of soft gelatin capsules offered by IOC Ltd.?
As part of our offer in IOC Ltd., we present various types of soft gelatin capsules, tailored to the diverse requirements of our customers. Our product range includes:
- 20 Oblong: These are large, elongated capsules, designed to contain a larger amount of active substances, which makes them ideal for applications requiring a formula rich in ingredients.
- 10 Oval: Medium-sized oval capsules that are an excellent choice for administering standard doses of supplements, combining convenience of use with effective delivery of active ingredients.
- 6 Oval: These slightly smaller oval capsules are perfect for dosing medium to small amounts of active substances, offering users comfort and precision.
- 3 Oval: The smallest of our oval capsules, designed to deliver small doses of ingredients, ensuring accuracy and ease of swallowing.
- 5 Drops Twist Off: Innovative capsules with Twist Off mechanism, easy to open and ideal for single-use, precisely dosed applications.
- 3 Drops Twist Off: A smaller version of our capsules with a Twist Off closure, also intended for single use, ensuring ease and hygiene of use.
Each of these capsules has been designed to ensure the highest availability of bioactive ingredients, as well as to meet the specific needs and expectations of our customers, both in terms of functionality and aesthetics.
What quality standards and certifications does your capsule production have? softgel?
Jako Contract Producer, IOC z o. o. proudly presents a comprehensive range of services, ranging from the design stage, through production processes, to the distribution of various products. Our portfolio includes functional and enriched foods, dietary supplements, products for special nutritional and medical purposes, as well as cosmetics and components. Our advanced procedures and management systems, such as CRM and Lean Management, support us in striving for continuous improvement and in implementing the assumptions of corporate social responsibility (CSR).
Our specialty, the production of soft capsules softgel, is carried out in accordance with strict quality standards, as evidenced by an extensive portfolio of certificates, including ISO 9001, 22716, GMP, HACCP, GHP and ISO 22000. These certificates not only demonstrate our commitment to delivering the highest quality products, but also compliance with international quality and safety standards. Thanks to our commitment to good manufacturing practices (GMP) and constant audits, we can ensure that our products not only meet, but often exceed, industry and regulatory requirements, allowing our customers to have full confidence in the solutions we offer.
Advantages of Soft Capsules
Softgels offer many advantages, such as faster absorption compared to tablets, the ability to encapsulate both liquid and semi-liquid ingredients, and better bioavailability. The use of a soft shell also allows for masking any unpleasant taste or odor of the active ingredients.
Capsule Production Softgel w IOC
Production capsules softgel w IOC combines innovative technologies with precise quality control, providing a product with exceptional flexibility and aesthetics. Here are the key aspects of this process:
Microstructure of the components
The precise selection of gelatin ensures the stability, transparency and elasticity of the capsules.
Innovative Plasticizers
Modern polymers increase the biodegradability of capsules and support sustainable development.
Advanced Mixing Techniques
High-precision mixers minimize the risk of defects in every batch.
Precision Forming
Innovative forming machines with monitoring sensors ensure quality control at every stage.
Quality control
Using artificial intelligence to monitor production enables proactive quality management.
Capsule Personalization
Flexibility in production allows for quick adaptation of capsules to individual customer needs.
The process of cutting capsules using a rotary die
Main Stages of Soft Capsule Production Softgel
1. Preparation of Ingredients
The production process of soft capsules begins with a meticulous selection of ingredients. Gelatin, the main ingredient of the capsule, can be of animal origin (from fish, beef or pork) or plant origin (agar, aliginate). Selecting the right source of gelatin is crucial, because its physicochemical properties (molecular weight, degree of hydroxylation) affect the elasticity, durability and solubility of the final capsule.
Plasticizers are added to capsules, most often glycerol, which improves the elasticity of the gelatin coating. Colors and flavors are also popular additives, which contribute to the attractiveness of the product, especially in the dietary supplement industry. Organoleptic attractiveness is important especially in the context of younger recipients.
2. Homogenization of the Filling Material
Soft capsule filling, which can be oil, suspension or other substances, also requires careful preparation. The key step is its homogenization, which ensures a uniform structure and minimizes the risk of chemical reactions of the ingredients. In modern production lines, ultrasonic and mechanical mixers are used to mix and homogenize the filling material, which allows for obtaining uniform emulsions.
It is also very important to control the temperature parameter, because some active ingredients are sensitive to high temperatures and can lose their properties during processing. For this reason, vacuum systems are often used, which allow mixing without introducing air, which in turn minimizes oxidation.
3. Gelatin Mass
After preparing the recipe, the next step is to obtain the gelatin mass. The coating components are heated in tanks to a specific temperature and then thoroughly mixed, which allows for obtaining a uniform consistency. An important aspect is the control of the viscosity and fluidity of the gelatin mass, which facilitates further capsule formation.
In modern soft capsule production equipment, both gelatin components and plasticizers are cooled and heated in appropriate heating systems. This allows for obtaining optimal mechanical properties of the coatings, which is crucial for the quality of the capsule.
4. Encapsulation Process
Encapsulation is a key step in which the gelatin mass is formed around the prepared capsule interior. The use of rotary die machines, which use two-shaft technology, allows for very precise dosing of the filler material. This allows for obtaining capsules with a uniform distribution and ideal dimensions.
At this stage, the gelatin ribbons that form the outer shell of the capsule are lubricated, which prevents them from sticking together in subsequent stages of production. Effective lubrication is essential to ensure proper slippage during the closing of the capsules under pressure. It is also crucial to precisely control the environmental conditions in order to achieve high capsule quality.
5. Drying and Stabilization
After the capsules are produced, they are dried. Removing excess moisture is essential to ensure that the capsules have the right hardness and elasticity. Modern plants use airtight drying chambers that allow controlled drying of the capsules in optimal temperature conditions.
6. Quality Control
Each stage of soft capsule production requires rigorous quality control. Maintaining quality standards is crucial for the final product, which is why capsules are tested for various parameters. Visual inspection, microscopic evaluation and chemical analysis ensure that the final product meets pharmacopoeial standards and meets market needs.
7. Cleaning and Polishing
After a thorough quality control, the softgels undergo a cleaning and polishing process. This crucial step is designed to remove any residual oil that may have remained on the surface of the capsules during previous production processes. The use of special polishing machines ensures a perfectly smooth and shiny surface, which not only increases the visual appeal of the product but also provides better resistance to external contamination. Good practices in this area are essential for the capsules to meet rigorous quality standards and be ready for packaging and distribution.
Innovations and Technologies for Soft Capsule Production Softgel w IOC
W IOC we use advanced production technologies such as liposomal and nano-micellization, which increase the bioavailability of active ingredients. Supercritical CO2 extraction ensures the purity and quality of our products without the use of chemicals. Microencapsulation allows for the controlled release of ingredients, improving their effectiveness and stability.
Commercialization of New Technologies
IOC collaborates with scientists around the world, providing innovative technologies for the production of dietary supplements, both its own and licensed.
Innovations and Technologies
We offer modern solutions such as nanoemulsions without synthetic emulsifiers, Atelocollagen and plant collagens VegiColl®.
Production Scaling
We specialize in transforming laboratory prototypes into mass production while maintaining the highest quality standards.
Distribution Strategies
We design integrated distribution strategies, including traditional channels and e-commerce, which maximizes product availability.
Ecological Practices
We use sustainable manufacturing practices, minimizing environmental impact and using renewable energy sources.
Product Personalization
We tailor products to individual customer needs, using advanced technologies to analyze consumer trends.
| 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 Technology | 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. |
Innovative Technologies Used in Production
In recent years, the soft capsule industry has experienced significant technological innovations that have introduced new quality into the production process.
- Automation Technologies: Modern production lines are largely automated. The introduction of robotic systems in the encapsulation process, including automated packaging machines, significantly increases efficiency and reduces the risk of human error. Automation also enables precise dosing and real-time quality control, which is crucial for maintaining product consistency.
- Artificial Intelligence and Big Data: The use of artificial intelligence algorithms and real-time data analysis has a significant impact on the quality of production. By using machine learning technology, companies can predict irregularities in production, which leads to optimized processes and reduced waste.
- Application of Intelligent Sensors: Modern sensors and monitoring systems enable close monitoring of process conditions, such as temperature, humidity and pressure, which helps maintain the high quality of the ingredients used and the capsules produced. Thanks to these technologies, companies can react in real time to any deviations, which improves the quality of the final product.
Sustainability in the Softgel Industry
Sustainability has become a key theme in softgel production. The industry is responding to changing consumer expectations and environmental regulations by implementing greener processes.
- Biodegradable Materials: In response to market needs, manufacturers are increasingly implementing bio-alternatives to traditional gelatin, such as vegetable gelatin (agar, carrageenan) and other biodegradable polymers. Their use allows the production of capsules that are more environmentally friendly, responding to the growing demand for ecological solutions.
- Waste Reduction: Optimizing production processes and implementing waste management methods aimed at minimizing them are an important element of the sustainable development strategy. Modern production lines often implement closed-loop circles, where waste from one production is reused in another.
- Energetic efficiency: Softgel manufacturers are investing in energy-saving technology, both in the design of production lines and in the processing processes themselves. The use of energy-saving devices and the optimization of energy consumption contribute to reducing the ecological footprint of companies.
Trends and Challenges in the Softgel Industry
The softgel industry faces a variety of challenges and trends that are shaping the future of production and consumption.
- Product Personalization: The growing interest in personalized dietary supplements entails the need to adapt products to individual customer needs. The use of advanced technologies allows the production of capsules adapted to specific health profiles, which increases their effectiveness and attractiveness.
- Increased Demand for Supplements: The growth of health awareness and pro-health trends is driving the growing popularity of dietary supplements, including softgels. Manufacturers must adapt their production lines to rapidly changing market expectations.
- Regulations and Compliance: The growth of the dietary supplement market also brings with it changes in safety and quality regulations. The industry must adapt its practices to strict standards to ensure that products are not only effective, but also safe.
- Consumer Education and Awareness: As consumers become more aware of their choices, manufacturers need to focus on educating and informing customers about the benefits of taking softgels. Investments in marketing strategies and information campaigns are key to building customer trust and loyalty.
