How Do They Dry Softgels?

Softgel capsules are a popular form of medication and supplement delivery due to their ease of swallowing, precise dosage, and high bioavailability. However, an essential step in their manufacturing process is drying softgels properly to ensure their stability, consistency, and longevity. Softgel dryers play a crucial role in this phase, removing excess moisture to prevent deformation, stickiness, and microbial contamination.

In this article, we will explore why drying is necessary, the different types of equipment used for drying softgels, and critical factors affecting the softgel drying process. We'll also discuss modern advancements in softgel dryers and how they influence product quality.

Why Is the Softgel Drying Process Necessary?

The drying process in softgel production is essential for several reasons:

• Moisture Removal: Softgel capsules contain gelatin, which retains moisture. If not dried efficiently, the product may become sticky or deformed.

• Structural Integrity: Proper drying helps softgels maintain their shape and prevent leakage.

• Shelf Stability: Excess moisture can lead to microbial growth or oxidation, reducing product shelf life.

• Consumer Safety: Undried or improperly dried capsules can degrade, leading to compromised efficacy and safety.

Typically, softgel manufacturers employ softgel dryers to ensure capsules undergo controlled drying without compromising their integrity.

What Equipment Should You Use to Dry Soft Gelatin Capsules?

The drying process involves specialized equipment designed to remove moisture efficiently while maintaining the physical and chemical properties of the softgel. The primary equipment used includes:

Tumble Dryer

A tumble dryer is the first stage of the softgel drying process. It rapidly removes surface moisture from freshly encapsulated softgels through controlled tumbling motion and airflow.

Features of a Tumble Dryer:

• High-speed drying: Reduces surface moisture quickly.

• Adjustable rotation speed: Prevents capsule deformation.

• Optimized airflow: Enhances drying efficiency.

• Temperature control: Prevents overheating and gelatin shrinkage.

Softgel Drying Trays

After initial drying in a tumble dryer, softgels are transferred to drying trays for gradual moisture removal. These trays allow uniform drying by exposing softgels to ambient or controlled humidity environments.

Advantages of Softgel Drying Trays:

• Even drying: Ensures uniform moisture reduction.

• Stackable design: Saves space in production areas.

• Custom materials: Trays are often made of food-grade plastic or stainless steel for hygiene.

Drying Tunnel

For high-production environments, a drying tunnel is used to automate the drying process. This system provides controlled temperature, humidity, and airflow conditions to gradually dry softgels without affecting their composition.

Benefits of a Drying Tunnel:

• Automated drying process: Increases efficiency.

• Precise humidity control: Prevents over-drying.

• Continuous operation: Reduces labor costs and enhances productivity.

A comparison of these drying methods is shown below:

Important Things Impacting the Softgel Drying Process

Several factors influence the efficiency and effectiveness of softgel dryers in removing moisture while maintaining product quality.

Gelatin Preparation

The gelatin formula used for softgel production significantly affects drying time. Key aspects include:

• Gelatin concentration: Higher concentrations require longer drying times.

• Plasticizers (e.g., glycerin, sorbitol): These impact how much moisture is retained in the softgel shell.

• Gelatin bloom strength: Affects capsule hardness and drying behavior.

Equilibrium Moisture Content

Softgels must reach an equilibrium moisture content (EMC), which is the ideal moisture level where the capsules remain stable without becoming brittle.

• Ideal EMC for softgels: Typically between 6-8% moisture content.

• Over-drying risks: Capsules may become brittle and crack.

• Under-drying risks: May lead to microbial growth and reduced shelf life.

Equipment Condition

The efficiency of softgel dryers depends on proper maintenance and calibration. Factors to consider include:

• Airflow consistency: Uneven airflow can lead to inconsistent drying.

• Temperature control: Overheating can degrade gelatin, while low temperatures may prolong drying.

• Filter cleanliness: Dust accumulation can impact airflow efficiency.

Conclusion

Drying softgels is a vital step in the softgel manufacturing process, ensuring product stability, safety, and efficacy. By utilizing equipment like tumble dryers, softgel drying trays, and drying tunnels, manufacturers can optimize the drying process to achieve the perfect moisture balance.

Key takeaways:

• The softgel drying process prevents capsule deformation and microbial contamination.

• Different types of softgel dryers are used depending on production scale and automation needs.

• Factors such as gelatin composition, equilibrium moisture content, and equipment condition significantly influence drying efficiency.

With advancements in softgel dryer technology, manufacturers continue to improve product quality while reducing energy consumption and drying time.

FAQs

1. How long does it take to dry softgel capsules?

The drying time varies based on equipment, gelatin composition, and environmental factors but typically ranges from 24 to 48 hours.

2. Can softgel capsules be air-dried?

While possible, air-drying is inefficient and inconsistent compared to using specialized softgel dryers such as tumble dryers and drying tunnels.

3. What happens if softgels are not dried properly?

Improper drying can lead to stickiness, leakage, microbial contamination, or brittleness, impacting product quality and shelf life.

4. What is the best humidity level for drying softgels?

The ideal relative humidity for softgel drying is 20-30%, depending on the formulation and drying method used.

5. How do manufacturers ensure uniform drying?

Manufacturers use automated drying tunnels, controlled airflow, and humidity-regulated environments to achieve uniform drying.