Troubleshooting Common Issues in Softgel Manufacturing

Softgel manufacturing involves a complex process that requires careful attention to detail to produce high-quality capsules. However, despite taking all the necessary precautions, issues may arise during the manufacturing process that can affect the quality of the final product. In this article, we will discuss some common issues that can occur during softgel manufacturing and how to troubleshoot them.

1. Filling Variations

One of the most common issues during softgel manufacturing is variations in filling volume. This can occur due to issues with the filling machine, including clogged nozzles or inconsistent filling speeds. To troubleshoot this issue, it is essential to check the filling machine and ensure that it is clean and properly maintained. It may also be necessary to adjust the filling speed to achieve consistent filling volume.

2. Capsule Shrinkage

Capsule shrinkage is another common issue that can occur during softgel manufacturing. This is when the capsule shell shrinks, causing the contents to be exposed. Capsule shrinkage can occur due to issues with the gelatin solution, such as improper preparation or overheating. To troubleshoot this issue, it is necessary to review the gelatin preparation process and ensure that the solution is properly prepared and maintained at the appropriate temperature.

3. Leaking Capsules

Leaking capsules can occur due to a variety of issues, including inadequate sealing or damage to the capsule shell. To troubleshoot this issue, it is essential to inspect the capsules carefully and identify the cause of the leakage. It may be necessary to adjust the sealing temperature or pressure, or to replace damaged capsule shells.

4. Discoloration

Discoloration of the capsule shell can occur due to issues with the gelatin solution or exposure to light and heat during the manufacturing process. To troubleshoot this issue, it is essential to review the gelatin preparation process and ensure that the solution is prepared correctly. It may also be necessary to improve the storage conditions of the capsules to prevent exposure to light and heat.

5. Size Variations

Variations in the size of the capsules can occur due to issues with the filling machine or capsule shell formation. To troubleshoot this issue, it is essential to inspect the capsule shells and ensure that they are consistent in size and shape. It may also be necessary to adjust the filling machine to achieve consistent filling volume.

6. Cracked Capsules

Cracking of the capsule shells can occur due to a variety of issues, including inadequate drying or exposure to environmental factors. To troubleshoot this issue, it is essential to review the drying process and ensure that the capsules are properly dried before inspection and quality control testing. It may also be necessary to improve the storage conditions of the capsules to prevent exposure to environmental factors.