Capsule leaks may be tiny, but they can cause major problems in softgel manufacturing. Keen to learn more about how the occurrence of leakers affects the production process, we interviewed 20 softgel manufacturers. Most of the interviewees worked in R&D, operations and quality in both health & nutrition and pharmaceutical companies. Here are the key findings:

Age-old problem

100 per cent of respondents said they had experienced leaking softgels at some point during the process (drying, production, storage, stability testing, transport and packaging). However, most leakers are detected during or after drying process, in rotating tumblers but also on trays. Furthermore, 85 per cent of softgel manufacturers had noticed a link between leaking softgels and their fill. According to the interviewees the occurrence of leakers is highly depending on the fill system. Lecithin, pastes and (herbal) powders are the most challenging fills. Interestingly, most softgel manufacturers accept leakers within certain parameters, imposing limits of between one and five per cent. This may demonstrate that a certain tolerance for leaker occurrence is necessary, as there has been no reliable solution to fully avoid leaking softgels.

Omega-3 fatty acids from fish, cod liver and krill oil are increasingly popular nutritional supplements, typically delivered in convenient, easy-to-swallow softgel gelatin capsules. Yet consumers can be deterred from using them by their unpleasant side effects – reflux (fishy burps) and aftertastes – which arise when the fill is released into the stomach.

Manufacturers can mitigate these side effects by applying an acid-insoluble, “enteric” coating to their softgels that delays release of the fill until it reaches the intestine. However, this adds time and cost to the production process, and often has to be carried out by a third party. When leading Spanish dietary supplement manufacturer Rioja Nature Pharma was searching for a more sustainable and cost-effective solution to offer its customers, GELITA’s Spanish distribution partner, DKSH Spain, saw the potential for GELITA^® EC’s unique, enteric-release technology…

When it comes to “better for you” snacks, nutritional content is key. But so, too, is optimal taste and texture. We at GELITA can help tick all three boxes

“Better for you” products, as the name suggests, are designed to be healthier options compared to traditional alternatives. These products typically offer improved nutritional profiles, reduced levels of ingredients such as sugar, salt and unhealthy fats, and can also include functional ingredients for additional health benefits.

Consumers are becoming increasingly aware of the role that nutrition plays in their health. As a result, healthier, fortified food options have great market potential – and that includes confectionery products too. But in order to win over consumers, they must deliver in terms of taste, texture and indulgence. Here, the right ingredients paired with our formulation, application and market know-how is a winning combination.

Softgel capsules are a hugely popular delivery method among consumers of medicines and nutraceuticals, but for manufacturers, creating perfect capsules can be hit and miss.

The market for softgels is buoyant. Grand View Research valued it at USD 7.67 billion in 2022 and predicts that it will grow at a CAGR of 6.9 per cent from 2023 to 2030.1 Consumers like softgels for several reasons, including ease of swallowing and effective masking of odor and taste. Softgels also offer good absortption, bioavailability and shelf life stability. However, during manufacture, things don’t always go according to plan and leakers are a common problem that can hamper quality as well as production efficiency.

There’s a thriving trend for holistic self-care, with growing numbers of consumers actively seeking natural, sustainable solutions for energy levels and mental and emotional wellbeing.[1] This has led to increased interest in plant-based nootropics – botanical ingredients that help boost cognitive function. Some of the most popular include ginkgo biloba, ginseng, guarana and L-theanine, which research suggests can positively affect memory, focus, alertness and mental energy.

Let’s get straight to the point: The market for gummy supplements is booming! Between 2018 and 2022, the fortified gummy category experienced an exponential compound annual growth rate (CAGR) of a whopping 37 per cent. But despite such growing demand, manufacturers have found it challenging to deliver a desirable texture using an efficient, starch-free process. Until now, that is. At GELITA, we have developed CONFIXX^® - a gelatin that can be processed starch-free yet still gives gummies their anticipated chewy texture.