•  Step One – Gelatin Preparation

Powdered gelatin is mixed with water until a liquid gelatin is formed in a reactor. The reactor serves as a gelatin-melting tank. It is important that this process is done quickly and that minimal air is in the gelatin. When color is added to the gelatin – it is done so by a high-speed vacuum mixer – again to decrease the amount of added air to the gelatin. The gelatin is stored in heated tanks until used.

•  Step Two – Encapsulation

Forming the Gelatin Ribbon The gelatin is supplied to the encapsulation machine through a gravity driven system. The gel is sent to the machine and two ribbons of gelatin are formed. The ribbons of gelatin are cooled and lubricated with non-toxic oil. The gelatin is now ready to be shaped and filled.

• Filling the Capsule

The two ribbons of gelatin are run through recessed dies of the desired shape and size. The ribbon of gelatin is forced into the recessed areas of the die by the chosen fill material. At the same time the capsule is filled within the die it is sealed and cut from the ribbon of gel.

•   Step Three – Drying of Capsules

Stage One – Capsules that have just been filled are very soft due to the amount of moisture they contain. Therefore they are sent immediately through a tumble dryer via a conveyor. The main purpose of the tumble dryer is to remove the thin layer of oil on the outside of the capsule as well as some of the moisture in the gelatin.

Stage Two – After being tumble dried, the capsules are placed on trays and moved into rooms that are climate controlled to continue drying. Air is circulated around the trays of capsules for up to 48 hours.

•   Step Four – Inspection

Before any capsules are packaged they are inspected for uniformity, proper filling and to make sure there are no air pockets in the gelatin or dimples in the shell.