Eliminating leaking softgels

Published: 12-Dec-2023

New EASYSEAL gelatin from GELITA simplifies softgel production and helps to cut costs

Gelatin expert GELITA is introducing a unique solution that enables manufacturers to optimise softgel production in one easy step.

By switching to the new EASYSEAL gelatin, manufacturers can enjoy significant reductions in leakers, lower processing costs and higher quality end products.

"Leakers" are softgels that lose their fill owing to faulty capsule seams and are a major cause of lost productivity and reduced yield for producers of softgels.

EASYSEAL overcomes the issue, providing additional benefits at the same time. The highly processable pharmaceutical grade gelatin optimises seam forming and enhances seam thickness and stability so that soft capsules are more resistant to physical stress during production and packing.

Its outstanding characteristics enable EASYSEAL® to seal capsules more reliably at higher machine speeds than other gelatins. EASYSEAL can also be used at higher speeds with ingredients (suspensions) that are normally complicated to fill in softgels, and for products that require special equipment such as double step die tooling.

As well as delivering higher capsule burst strength, EASYSEAL is less dependent on sealing temperature than other gelatins and has superior drying properties. This brings advantages in terms of energy efficiency and enhanced production capacity.

Jessica Pfoehler, Global Marketing, Business Unit Performance Solutions, GELITA AG, says: “Many manufacturers tolerate a reject rate of up to 5% in soft capsule production due to leakers. With EASYSEAL, this common industry problem will be a thing of the past — simply by changing one parameter: the gelatin.”

GELITA is the first gelatin manufacturer to address the problem of leakers. Its intervention comes at a time when trends in nutritional ingredients and APIs mean soft capsules manufacturers are given increasingly challenging product requests, and cost optimisation is more crucial than ever.

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Following pilot trials conducted with the University of Heidelberg, Germany, proof-of-concept has been demonstrated under real industrial production conditions by several softgel manufacturers.
EASYSEAL is suitable for use with food supplements, Rx medicines and over the counter health and wellness products.

It is available in bovine and porcine forms and is produced in line with FDA regulations, HACCP, ISO9001:2015 and FSSC22000. A respective C-DMF (China Drug Masterfile) is available to ease entering the China market.

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