The softgel encapsulation machine line is a sophisticated and integrated system designed to efficiently produce high-quality soft gelatin capsules. This line encompasses a series of sequential processes, each relying on specific equipment to ensure the integrity, uniformity, and quality of the final product. Below is a detailed breakdown of the entire production line, including the technological processes and the equipment involved.

1. Filling Material Preparation & Gelatin-melting

This is the initial and crucial stage of the softgel production process, laying the foundation for the subsequent steps.

In the filling material preparation phase, the active ingredients, excipients, and other necessary components are precisely measured according to the predefined formulation. These materials are then transferred to the Dosage Tank,a specialized equipment designed with mixing and homogenizing functions. The Dosage Tank ensures that all the ingredients are thoroughly blended to form a uniform mixture, which is essential for the consistent potency and quality of the final softgels. The mixing process is carefully controlled in terms of speed and duration to avoid any degradation of the active ingredients.

Simultaneously, the gelatin-melting process takes place. Gelatin, the main material for the capsule shell, is mixed with water and other additives (such as plasticizers) in the Gelatin-melt Tank.The Gelatin-melt Tank is equipped with heating elements and stirring devices. The temperature is precisely regulated to melt the gelatin completely while preventing it from overheating, which could affect its properties. The stirring ensures that the mixture is homogeneous, resulting in a smooth gelatin solution.

After the filling material is prepared, it is transferred to the Liquid Storage Tank for temporary storage. The Liquid Storage Tank is designed to maintain the stability of the filling material, with features such as temperature control (if necessary) to prevent any changes in its physical or chemical properties before it is used in the next stage.

The melted gelatin, on the other hand, is moved to the Gelatin Storage Tank.This tank is an insulated container that keeps the gelatin at a constant temperature, ensuring it remains in a fluid state and maintains its viscosity, which is critical for the proper formation of the capsule shells in the subsequent process.

2. Soft Gelatin Filling

The next stage is the soft gelatin filling, which is carried out by the RJN Series Softgel Encapsulation Machine. This machine is the core of the production line, integrating multiple functions to form the softgels.

The RJN Series Softgel Encapsulation Machine receives the filling material from the Liquid Storage Tank and the gelatin solution from the Gelatin Storage Tank. The machine works by forming two ribbons of gelatin from the gelatin solution. These ribbons are brought together between a set of rotating dies, which have cavities of the desired shape and size for the softgels.

As the dies rotate, the filling material is injected into the space between the two gelatin ribbons. The pressure from the dies seals the gelatin ribbons around the filling material, forming individual softgel capsules. The precision of the RJN Series Softgel Encapsulation Machine ensures that each capsule has a consistent amount of filling material and a uniform shell thickness.

3. Forming and Drying

After the softgels are formed in the encapsulation machine, they enter the forming and drying stage. This step is crucial to give the softgels their final shape and to remove excess moisture from the capsule shells.

The newly formed softgels are delicate and need to be handled carefully. They are transferred to the Tumble Dryer, where they undergo a controlled drying process. The Tumble Dryer consists of a rotating drum that tumbles the softgels gently. This tumbling action ensures that the softgels are dried uniformly, as each capsule comes into contact with the drying air.

The drying air in the Tumble Dryer is regulated in terms of temperature, humidity, and flow rate. The parameters are set based on the specific characteristics of the softgels, such as their size and the composition of the gelatin shell. The drying process reduces the moisture content of the capsule shells to the desired level, making them firm and stable.

4. Pill Cleaning

Once the forming and drying process is complete, the softgels proceed to the pill cleaning stage. During the previous processes, the softgels may accumulate dust, debris, or excess gelatin on their surfaces. The pill cleaning step removes these impurities to ensure the cleanliness of the softgels.

Specialized cleaning equipment is used for this purpose, which can vary depending on the production line setup. Common methods include using air jets to blow away loose particles or using a gentle washing process with purified water, followed by a quick drying step to remove any residual moisture.

5. Final Drying

After cleaning, a final drying step may be required to ensure that any moisture picked up during the cleaning process is removed. This is especially important to prevent microbial growth and to maintain the stability of the softgels during storage.

The final drying can be done using similar equipment to the forming and drying stage, such as a Tumble Dryer, but with adjusted parameters to ensure thorough drying without over-drying the capsules, which could lead to brittleness.

6. Inspection/Polishing

The next stage is inspection and polishing. Inspection is a critical quality control step to ensure that only qualified softgels proceed to the next stage. Trained personnel or automated inspection systems examine the softgels for any defects, such as cracks, holes, uneven filling, or improper shape. Defective capsules are removed from the production line.

Polishing is often carried out simultaneously or after inspection. This process gives the softgels a smooth and shiny surface. Polishing can be done using specialized polishing equipment that gently rubs the softgels against a polishing material, removing any remaining surface imperfections and enhancing their appearance.

7. Packaging

After passing inspection and polishing, the softgels are ready for packaging. The packaging process is designed to protect the softgels from external factors such as light, moisture, and oxygen, which could affect their quality.

Two common packaging lines are used in this stage: the Tablet Capsule Counting & Filling Production Line and the Blister Packing Cartoning Machine Line.

The Tablet Capsule Counting & Filling Production Line is highly efficient for counting and filling softgels into bottles. It uses advanced sensors and counting mechanisms to accurately count the required number of softgels, which are then smoothly filled into bottles. This line can handle different bottle sizes and has the capability to adjust the counting speed according to production needs. After filling, the bottles are sealed, and labels with batch numbers, expiration dates, and other relevant information are applied.

The Blister Packing Cartoning Machine Line, on the other hand, first forms blisters on a plastic sheet. The softgels are then accurately placed into these blisters by automated equipment. The blister sheet is then sealed with a aluminum foil to protect the softgels. After blister packing, the blister cards are transferred to the cartoning part of the line, where they are folded into cartons. The cartons are sealed, and necessary information is printed or labeled on them.

Both packaging lines are automated to ensure efficient and accurate packaging of the softgels, meeting different packaging requirements and market demands.

8. Final Product Storage

The final step in the production line is the storage of the packaged softgels. The storage area must be controlled to maintain optimal conditions for the stability of the product.

The storage facility should have a controlled temperature and humidity level, typically cool and dry. The packaged softgels are stored on pallets or in shelves, ensuring proper ventilation and easy access for inventory management. It is important to follow proper storage guidelines to ensure that the softgels retain their quality and efficacy until they reach the end-user.

In conclusion, the softgel encapsulation machine line is a highly coordinated system that involves multiple processes and equipment working together to produce high-quality soft gelatin capsules. Each stage of the production line is critical, and strict control of parameters ensures the consistency, safety, and efficacy of the final product.