Gelatin capsules offer an effective and reliable packaging solution in the pharmaceutical and supplements industry.
You can fill different products such as pellets, powder or liquids. However, unlike powder and pellets, liquid filling requires specialized capsule filler machine with dosing system designed for liquids.
If you are planning to fill gelatin capsules with liquid, we are going to show you how to handle the entire process.
Step 1: Choose the Right Size of Empty Capsules
You will need to choose the right sizes of hard gelatin capsules based on your needs. The details of these sizes to consider include
- Sizes
Under sizes, it is best to use standard empty capsules. You will find sizes 00, 0, 1, and 2. Size 0 is ideally used for quite a number of supplements. Size 00, on the other hand, will offer you a larger capacity level.
- Considerations
Always consider your ideal dose volume before you choose the capsule size. Again, the capsule size needs to be compatible with the type of liquid that will be filled in.
Step 2: Know Liquid to Fill in Capsules
Knowing the liquid properties will help you choose a perfect dosing system. It is important to pay attention to various liquid flow characteristics. In fact, it is a perfect way to ensure accuracy and consistency in the entire filling process.
- Liquid or Mixture Requirements
Your gelatin capsules used should be compatible with the liquid you intend using. Also, it must be chemically inert and not make capsules degrade.
- Stabilizing
The best excipients you can use to stabilize liquids that will be used as fill include lipophilic vehicles, emulsifiers, or solubilizers.
- Viscosity
Never forget to adjust your liquid viscosity to ensure the ideal filling is reached. Doing this prevents issues of leaks too.
Step 3: Choose Capsule Filling Machine
As mentioned earlier, capsule fillers for liquids require unique dosing system. Depending on your production capacity, you can choose manual fillers or fully automatic filling machines.
Usually, for clinical trials or R&D, a manual filling machine will work well. However, for large scale production, we recommend you choose automatic capsule filling machine.
- Manual Fillers
You will need tools like manual capsule filling trays, syringes, or droppers. Also, it is ideal for your small-scale productions
- Automated or Automatic Filler
You will need an automatic liquid capsule filling machine equipped with precision pumps. With this machine, however, you are able to handle higher volumes and ensure uniform fill weights.
Step 4: Fill your Empty Capsules with Liquid
Let’s explore two different ways you can fill empty gelatin capsules with liquid products:
· Manual Filling Gelatin Capsules with Liquid
Step 1: Put Empty Capsules in Capsule Filling Machine
You will begin by placing the capsule bodies into the ideal slots of the filling tray.
Step 2: Separate Empty Capsules
Go on by making sure all capsule bodies are separated from the caps.
Step 3: Use Dropper to Fill Gelatin Capsules with Liquid
Using your dropper or syringe, carefully dispense the liquid into capsule bodies one by one.
Step 4: Put Top Part of Capsule Filler
After step 3 is done, align and place capsule caps onto the filled bodies.
Step 5: Join Capsules and let it Seal
Finally, you will have to press the capsule halves together to have a strong seal.
· Automatic Filling Empty Capsules with Liquid
Step 1: Choose Automatic Liquid Capsule Filler
You start by choosing an ideal or suitable machine for your production scale and liquid type.
Step 2: Load Empty Capsules in Machine Hopper
Move on to put empty capsules into the filling machine’s hopper.
Step 3: Machine Orients and Separated Capsules
With the hopper filled, the machine orients and separates capsules automatically.
Step 4: Dosing Liquid into the Empty Capsules
With separation completed, precision pumps from the machine are used to fill each capsule with the ideal liquid amount.
Step 5: Closing and Sealing Filled Capsules
With filling done, capsule caps are placed and sealed automatically onto the bodies.
Step 6: Drying Capsules and Discharging
Now, all filled capsules are dried to get rid of any residual moisture. Then, discharged or released to be packaged.
Step 5: Check Quality of Capsules Filled with Liquid
The last and most important part in capsule filling process is quality control. You should ensure all capsules have the right liquid quantity and they are properly sealed.
- You will have to perform leak tests to ensure your capsules are well sealed.
- Each capsule will have to be checked to ensure it contains the right liquid amounts.
- All inconsistencies of the capsules will need to be checked.
FAQs
Can you put liquid in gelatin capsules?
Yes, you can, provided the liquid is compatible with the capsule material you are using.
What are the benefits of capsules filled with liquid?
You get to have better bioavailability, and they are easier to swallow than tablets are.
What are the limitations of filling gelatin capsules with liquid?
You can experience limitations like probable leaks, sealing issues, and the need for specialized equipment.
