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Rotary Die Process


In this process, two plasticized gelatin ribbons (prepared in the rotary-die machine) are continuously and simultaneously fed with the liquid, semiliquid or paste fill between the rollers of the rotary die mechanism. The forced injection of the feed material between the two ribbons causes the gelatin to swell into the left- and right-hand die pockets which govern the size and shape of the softgels as they converge. As the die rolls rotate, the convergence of the matching dies pockets hermetically seals and cuts out the filled capsules.

Plate process

This is the oldest commercial process used in the manufacture of soft gelatin capsules. In this process, a warmed sheet of plain or coloured plasticized gelatin is placed over a die plate having a number of depression or moulds or numerous die pockets. By applying vacuum, the sheet is drawn into these depressions or pockets to form capsule wells. The capsule wells are then filled with medication-containing liquid. A second sheet of gelatin is carefully placed on top of the filled wells followed by the top plate of the mould. Pressure is then applied to the combined plate to form, seal and cut the capsules into individual units. This method is used for small scale preparation of soft gelatin capsules and capsules formed generally, had one flat side.

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