What to Know Before Soft Gel Supplement Manufacturing
Release time:
2025-11-27
Softgel supplements remain one of the most in-demand dosage forms in global nutrition markets, favored for excellent bioavailability, easy swallowing, and the ability to encapsulate functional oils and complex active ingredients. But before a brand or distributor starts soft gel supplement manufacturing, there are critical technical, regulatory, and cost considerations to clarify in advance.
This guide is written from the perspective of buyers seeking softgel OEM/ODM services and will help ensure smoother, faster, and more cost-effective production.
1. Understanding the Softgel Manufacturing Landscape
Why Brands Choose Soft Gel Supplements
Softgels offer several technical advantages:
High absorption rate due to dissolved or suspended actives
Better stability for sensitive lipid-based ingredients
Premium appearance and consumer acceptance
Ability to encapsulate complex blends (oils + powders + pastes)
Market Demand & Regulatory Expectations
As markets like the United States, Europe, and Southeast Asia tighten regulations, buyers are required to:
Validate ingredient safety and legal status
Provide accurate label claims
Ensure traceability from raw material to final batch
A professional manufacturer can guide brands through compliance requirements to prevent delays.
Common Misunderstandings Before Starting Production
Many new brands mistakenly assume:
All softgels have the same shell material
Any formula can be filled directly
Stability tests are unnecessary
Packaging can be finalized later
These misconceptions often lead to cost overruns or production delays.
2. Defining Your Softgel Product Concept Clearly
Before production, your manufacturer will ask for a clear product concept. The clearer the concept, the faster the development.
Ingredient Type
Softgels are ideal for:
Fish oil, algal oil, MCT oil
Herbal extracts dissolved in carrier oils
Coenzyme Q10, vitamin E, astaxanthin
High-viscosity pastes
Powders typically require suspension agents to ensure even distribution.
Softgel Size, Shape, and Swallowability
Common sizes range from 160 mg to 3000 mg.
Choose based on:
Target user age
Country preference
Daily dosage requirement
Target Customer & Product Positioning
Examples:
Beauty-from-within → small pink softgels
Sports nutrition → oversized 1500 mg softgels
Vegan markets → plant-based softgels only
Early Stability Considerations
Your formula must be evaluated for:
Oxidation risk
Moisture migration
Color changes
Shell hardening or softening
Stability issues resolved early save 4–6 weeks later.
3. Preparing Your Formula Before Manufacturing
Oil-soluble vs Water-soluble Actives
Only certain actives behave well in an oil matrix.
Water-soluble nutrients must be:
Converted into emulsions, or
Bound with carriers
Poor compatibility leads to phase separation inside the softgel.
Bioavailability Requirements
Some ingredients require:
Self-emulsifying technology
Nano-emulsion systems
Structured lipids
If these are needed, costs and MOQ will differ.
Interaction With the Gelatin/Plant Shell
Some ingredients soften or harden the capsule shell.
Testing prevents:
Leakage
Shell contraction
Sticky surface formation
Testing for Oxidation, Viscosity, and Filling Behavior
Manufacturers conduct:
Peroxide value checks
Viscosity curve tests
Encapsulation simulation
This ensures smooth encapsulation at production speed.
4. Selecting the Right Softgel Capsule Type
Gelatin Softgels
Most widely used. Excellent sealing and cost-effective.
Plant-Based Softgels
Made from starch, carrageenan, or alternative polysaccharides.
Required for vegan or religious markets.
Two-Color or Specialty Softgels
Useful for branding and premium appearance.
Common options:
Two-color swirl
Transparent + opaque dual shell
Metallic sheen effect
When to Use Enteric Coating
If targeting delayed release (e.g., omega-3 anti-reflux), enteric technology may be recommended.
5. Choosing a Professional Soft Gel Supplement Manufacturing Partner
GMP Certification & Facility Scale
A strong manufacturer should demonstrate:
GMP, ISO, HACCP standards
Large-scale encapsulation capacity
Complete QC laboratory
Customization Capability
Ideally, they should support:
Multiple capsule sizes
Custom colors and opacity
Advanced polishing and surface technology
Small-batch sampling before mass production
Design & Packaging Support
Good packaging directly affects brand perception.
Look for partners offering:
Bottle & box design
Label creation
Premium finishes (UV, hot stamping, laser, embossing)
Quality Control and Traceability
Every batch should include:
Heavy metal testing
Microbial testing
Active ingredient assay
Stability data
6. Cost Factors You Should Evaluate Before Production
Raw Material Cost and Market Volatility
Fish oil, gelatin, plant-based shell materials, and specialty extracts may fluctuate monthly.
Minimum Order Quantity (MOQ)
Softgel MOQ is typically 100,000–300,000 capsules, depending on:
Size
Color
Shell type
Capsule Type & Special Effects Pricing
Two-color and plant-based softgels increase cost.
Packaging Complexity
Blister packaging, glass bottles, and custom boxes add cost.
Hidden Costs Many Buyers Neglect
Formula adjustment
Stability testing
Freight and customs
Packaging mold fees
A transparent manufacturer will provide a full cost breakdown.
7. Timeline & Production Workflow to Expect
Formula confirmation
Sample preparation
Encapsulation & shaping
Drying and polishing
QC testing
Packaging
Final inspection and COA issuing
A typical softgel project requires: 30–45 days.
8. Pre-Production Checklist for Buyers
Before starting soft gel supplement manufacturing, ensure you have:
Final formula
Certificate of ingredient legality
Packaging plan ready
Stability test plan
Clear delivery timeline
Logistics arrangements
This avoids last-minute delays.
9. How a Trusted Manufacturer Simplifies the Process
A good partner not only produces capsules but also guides you through formulation, design, testing, packaging, and compliance.
To explore professional softgel manufacturing services, you may visit our website www.sdrxsw.com
10. FAQs About Soft Gel Supplement Manufacturing
1. What is the usual MOQ for softgel production?
Most manufacturers require 100,000–300,000 capsules, depending on the technical difficulty.
2. Can I customize the color and shape of softgels?
Yes. You can customize size, color, opacity, dual-color, and surface finish.
3. How long does it take to develop a custom softgel formula?
Samples typically take 7–15 days. Mass production requires 30–45 days.
4. Are plant-based softgels more expensive?
Yes. Plant-based materials cost more and require slower encapsulation speed.
5. Can I send my sample for matching?
Absolutely. OEM suppliers can reverse-engineer based on content, viscosity, and capsule shell structure.
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