Leaks in softgels are a persistent challenge in the production process, resulting in increased costs, wasted resources and significant environmental impact. Every time a softgel capsule leaks, it’s not just the product that’s lost but its expensive contents. This then contaminates machinery and other capsules, resulting in additional cleaning and production downtime. This means not only wasted materials but also higher energy use and additional labor costs, all of which add to the environmental and financial burden. If you’re in the softgel production game, you’ll know this scenario only too well.
In our survey of market-leading softgel producers, all respondents reported experiencing leakers during softgel production. To tackle this, many are forced to make frequent adjustments to machine speed, gel mass, drying times and temperatures, and storage conditions, as well as packaging and transport. However, these can all take a toll on productivity. But there is a simple, cost-effective solution - our latest innovation EASYSEAL®, which is designed to reduce leakers without compromising on effectiveness.
Faster, Smoother Processing
Our specialized pharmaceutical grade gelatin EASYSEAL® is known for its ability to significantly decrease leakers. But its benefits extend far beyond that, as reduced leakers result in a smoother, faster manufacturing process with fewer disruptions and higher output. By switching from common gelatin to EASYSEAL®, you’re not only minimizing leaks but also optimizing production, thus eliminating the need for constant adjustments to machine speed, storage conditions and packing methods.
Now let’s dig a little deeper into what makes EASYSEAL® so effective, particularly from a sustainability perspective. It’s suitable for any type of softgel and can increase capsule seam thickness by up to 50 per cent. This results in more robust capsules with enhanced burst strength and improved tolerance during handling, even at high machine speeds or with thinner ribbons – settings that would typically lead to high leak rates with standard gelatin.
As a result, the process becomes more efficient. Rather than losing valuable and often costly materials, EASYSEAL® allows for a reduction in gelatin ribbon without compromising on softgel quality, resulting in the use of fewer materials. In fact, trials revealed that the gelatin ribbon can be made approximately 15% thinner, allowing for a 15% increase in the number of capsules produced from the same amount of gel mass. This not only enhances productivity but also offers substantial cost-saving potential.
Save Time and Money
Another key sustainability advantage of EASYSEAL® is a shorter drying time. Thanks to its innovative gel mass, which contains less water, EASYSEAL® capsules can dry up to 50 per cent faster than those made with standard gelatins, thus increasing throughput.
In industrial trials, while other products required more than 1.5 days to reach the desired hardness, EASYSEAL® capsules achieved the same in half the time.
All of these benefits demonstrate that switching to EASYSEAL® is not just about reducing leakers; it’s about adopting a more sustainable and effective approach to softgel production. With EASYSEAL®, you’re guaranteed smoother, more consistent operations and output, with reduced energy usage, lower costs and less waste for more resource-efficient, cost-effective production.
