How softgels are made
A softgel is an oil-based fill sealed inside a gelatin (or plant) shell, formed and cut in one continuous rotary-die step. It is the format for oils — fish oil, pumpkin seed oil, oregano oil, astaxanthin — and for anything that needs protection from air.
1. Fill preparation
The active oil is blended with a carrier (olive, MCT or sunflower oil), antioxidant (mixed tocopherols) and, for powders in oil, a suspending agent (beeswax or lecithin). The blend is mixed under vacuum to remove air, which would otherwise expand in the capsule and cause leaks. Fill weight is set per SKU: 500 mg for oregano oil, 700 mg for pumpkin seed oil, 1,000 mg for fish oil.
2. Shell preparation
Gelatin (or a plant-based blend), glycerin and water are melted into a gel mass, coloured if required, and de-aerated. Shell options: bovine gelatin (standard; halal-certified source available), fish gelatin (halal, kosher, pescatarian), plant-based (vegan; slightly higher cost and longer drying).
3. Rotary die encapsulation
Two gelatin ribbons are cast, run over a pair of rotating dies, and the fill is injected between them at the moment the dies press the two halves together — forming, filling and sealing in one motion. Fill weight is checked every 15 minutes; the seam is inspected for leaks.
4. Drying
Fresh softgels are tumbled to set the shape, then tray-dried 12–24 hours until shell moisture reaches 6–10%. Under-dried softgels stick and deform; over-dried ones crack. This step sets softgel lead time the way curing sets gummy lead time.
5. Inspection, polishing, packing
Softgels are polished to remove surface oil, passed through a size screen and visual inspection (leakers, doubles, dents), then bottled with induction seal, or pouched for large counts (180–300 pieces).
QC release
| Test | Why |
|---|---|
| Fill weight and weight variation | Dose accuracy (±5%) |
| Disintegration | Shell dissolves in ≤ 30 min |
| Shell moisture | Stability, no sticking or cracking |
| Peroxide + anisidine (oils) | Rancidity; TOTOX reported |
| Active assay | EPA/DHA, carvacrol, astaxanthin content vs label |
| Heavy metals, microbial | Safety |
What drives cost
- Active oil grade — concentrated EPA/DHA (600+ mg per 1,000 mg) costs several times standard 30% fish oil; carvacrol-standardised oregano costs more than crude oil.
- Shell type — plant-based and fish gelatin cost more than bovine.
- Count per pack — 60 / 120 / 180 / 240 / 300; larger counts lower the per-piece packaging share.
- Enteric coating — extra step.
Our softgel SKUs — pumpkin seed oil, fish oil, oregano oil, astaxanthin, black walnut, nattokinase — are in the catalog. Halal shell options are on the halal page.
Frequently asked questions
Can softgels be vegan or halal?
Yes. Plant-based shells (carrageenan/starch) are vegan. Fish gelatin and halal-certified bovine gelatin shells cover halal and kosher needs. Porcine gelatin is not used in our facility.
Why does fish oil need extra testing?
Omega-3 oils oxidise. We test peroxide and anisidine values (TOTOX) on incoming oil and on finished softgels, and add natural tocopherols as antioxidant. Rancid fish oil is the number one complaint in the category; a low TOTOX number on the COA is a selling point.
What sizes do you fill?
From 300 mg (astaxanthin, oregano) to 1,000 mg (fish oil) and 1,200 mg. Oblong and round shapes; clear, amber or opaque coloured shells.
Enteric coating?
Available for fish oil and probiotics to avoid reflux and protect actives from stomach acid; adds a coating step and a few days.