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p
Formulate What?
p
Formulate a Softgel
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| Basic
formulation information on formulating, developing and manufacturing
softgel pharmaceutical or nutritional products. If you have
a specific question, please email us |
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| 1]
What is a softgel?
A
softgel (a.k.a., a soft gelatin capsule) is a solid capsule
(outer shell) surrounding a liquid or semi-solid center (inner
fill). An active ingredient can be incorporated into the outer
shell, the inner fill, or both.
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Advantages of softgels: |
| Ease
of Use |
Easy
to swallow, no taste, unit dose delivery, tamper-proof |
| Versatile |
Wide
variety of colors, shapes, and sizes.
Accommodates
a wide variety of compounds filled as a semi-solid, liquid,
gel or paste.
Immediate
or delayed drug delivery.
Can
be used to improve bioavailability by delivering drug in solution
or other absorption enhancing media.
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3)
Disadvantages of softgels:
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Requires
special manufacturing equipment
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Stability
concerns with highly water soluble compounds, and compounds
susceptible to hydrolysis
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Limited
choices of excipients/carriers compatible with the gelatin
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4)
The outer shell is composed of a gelatin or potato starch
matrix.
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Gelatin
matrix consists of gelatin, plasticizer, solvent and
optional ingredients such as flavors and colorants.
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Gelatin
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bovine, porcine, or piscine (fish) origin. Comes
in a variety of bloom strengths, the higher the
bloom strength, the more resilient the gel. Most
oil based fills are encapsulated using a bloom
strength of 150. When polyethylene (PEG) based
fills are used, a higher bloom strength is generally
used.
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The
limitations of bovine (i.e. bovine-related
diseases) and porcine (i.e. not kosher)
gelatin may be overcome by piscine (fish)
gelatin.
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Plasticizer
- Glycerin
and Sorbitol Special
are the two most common plasticizers. Glycerin
is generally used with oil based fills. Sorbitol
Special is used with PEG based fills. Sorbitol
is not soluble in PEG and therefore will not leach
out of the shell into the PEG based fill like
Glycerin would. Sorbitol Special is formulated
to inhibit sorbitol from crystallizing out in
the gelatin shell. Do not substitute Sorbitol
for Sorbitol Special.
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Solvent
- Water
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Optional
Ingredients -
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Colors |
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Flavors |
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Potato
starch matrix
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This
is a smooth, transparent substance resembling gelatin,
which is neutral in taste and color, easily digestible
and of plant origin, and therefore, the concerns
of certain bovine related diseases are not an issue,
and they offer a gelatin free alternative for vegetarians
and vegans. Currently, available from Swiss Caps
under the name Vegagels®. |
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5]
There are three primary types of inner fill materials:
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Neat
Substance, especially oily liquids
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Solution
Fills: Active dissolved in a carrier
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Oils
such as soybean oil and Miglyol 812 (neutral oil,
triglycerides of medium chain fatty acids)
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Polyethylene
Glycols: especially PEG 400 -600
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Other
solvents: Any other solvent which doesn't degrade
or solubilize the gelatin shell, i.e., dimethyl
isosorbide, surfactants, diethylene glycol monoethly
ether
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Optional
Ingredients:
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Water
or alcohol: up to 10% w/w, if needed for
solubility
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Glycerin:
1 to 4% w/w to retard the migration of the
glycerin out of the shell into the fill
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Polyvinylpyrrolidone:
Up to 10% w/w used in combination with PEG,
can increase drug solubility, and also improve
stability by inhibiting drug recrystallization
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Suspension
Fills: Active dispersed in a carrier
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Suspensions
can accommondate about 30% solids before viscosity
and filling become a problem |
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Suspensions
can be heated up to 35ºC to decrease viscosity
during the filling process |
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Suspended
solids must be smaller than 80 mesh -- mill or
homogenize before filling to prevent needles from
clogging during filling. |
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Carriers
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Oily
mixtures:
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Traditional:
Soybean Oil with beeswax (4-10% w/w)
and lecithin (2-4% w/w). The lecithin
improves material flow, and imparts
some lubrication during filling. Add
enough beeswax to get a good suspension,
but avoid creating a non-dispersible
plug.
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Gelified
Oil (e.g. Geloil® SC), a ready to use
system composed of soybean oil, a suspending
agent, and a wetting agent. Simplifies
the manufacturing process, and avoids
batch to batch and supplier to supplier
variability.
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Polyethylene
glycol
PEG
800 -1000 for semi-solid fills
PEG
10,000 -100,000for solid fills
Or
mixtures of the above.
Heat
up to 35ºC to make fluid enough for filling. |
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Glycerides
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Glycerides
of long chain fatty acids (e.g. Gelucire®
33/01). Hydrophobic with surfactant
properties.
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Optional
Ingredients:
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Surfactant:
sorbitan derivatives such as polysorbate
80 or lecithin.
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For
hydrophobic drugs dissolved or dispersed
in an oily matrix, a surfactant of HLB
10 will increase the dispersibility
of the product in aqueous fluids and
also may improve bioavailability.
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6]
Incompatibilities:
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Avoid
aldehydes which can lead to cross linking (pellicle formation)
of the gelatin, and poor dissolution of the gelatin capsule
in water. This may be overcome by adding enzymes to the
dissolution media, (see FDA Guidelines) |
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Drugs
sensitive to water can degrade (e.g. ranitidine) or undergo
polymorphic conversion (e.g. terazosin). |
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Compounds
(especially those of high water solubility) can migrate
from the fill into the shell or get trapped in a hydrophobic
matrix resulting in poor dissolution and loss of bioavailability. |
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Need
a supplier of excipients, ingredients, packaging materials or eqquipment
to formulate, develop or manufacture a soft gel pharmaceutical or
nutritional product? Submit in Excipients
Express!!!
7)
Soft Gelatin Encapsulation Processes and Equipment
Rotary
Die process
Two
ribbons of gelatin are fed continuously into a rotating die assembly
and are simultaneously formed into the two halves of a capsule.
The ribbons converge adjacent to a fill injector. The fill injector
is actuated by a pump which measures and dispenses the appropriate
volume of fill material into the capsules. The filled capsules are
subsequently sealed as the die assembly rotates. This process permits
accurate and reproducible fill uniformity.
Pump
heads are available for fill weights as low as 100 mg. For oral
dosage forms, the fill weight ranges from 100 mg up to about 1 gram.
The
following should be monitored/controlled:
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Gelatin
temperature |
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Fill
temperature |
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Ribbon
thickness |
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Seal
or seam width |
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Fill
quantity |
Following
encapsulation, the capsules undergo drying in a tumble drying tunnel
with an elevated temperature and a large volume of forced air. From
the drying tunnel, the capsules are transferred onto trays and placed
into a low humidity drying room.
The
following should be monitored:
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Gelatin
moisture |
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Fill
moisture |
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Capsule
hardness |
Drying
is a dynamic process, and the goal is to have the gelatin shell
return to it's equilibrium moisture content in the range of 6 -
8%.
Oil fills dry faster than PEG fills, and typically reach a shell
moisture content of 6 to 8% within 24 hours.
If
water migrates into the fill, it needs to migrate back out or at
lease be in equilibrium with the moisture content of the shell
for good stability. This is more typical of the PEG fills. These
can take 7 to 10 days to reach acceptable moisture levels, and may
still contain up to 10% water after drying.
Are
you a manufacturer or supplier of pharmaceutical grade, USP grade
or food grade ingredients, chemicals, or packaging materials used
in soft gel pharmaceutical or nutritionals ? If so , email us at pformulate@pformulate.com
to find out how to have your products listed in our soft-gel directories.
Pformulate/01/02/2003
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Express |
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to find a supplier to formulate a film coating, softgel, tablet,
gluten-free or gum based pharmaceutical or nutraceutical ? Simply
submit in Excipients
Express Requests ! |
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