Gelcaps

Empty Hard Gelatine Capsule

Introduction

Gelcaps (Pakistan) Limited is a pioneering company in the manufacturing of empty hard gelatin capsules in Pakistan. Recently, the company has expanded its operations to include the production of its own gelatin, as well as establishing a pharmaceutical plant to manufacture high-end quality products. This vertical integration allows Gelcaps Pakistan Limited to control the quality and consistency of its raw materials and finished products, enhancing its reputation as a trusted partner in the pharmaceutical and nutraceutical industries. Additionally, Gelcaps Pakistan Limited is now catering to the food sector by supplying high-quality gelatin under the brand name of GPL Halal Gelatin for various culinary applications.

Cleanliness & Hygienic Condition

Every person entering the manufacturing areas wear proper uniform appropriate to the operations to be carried out.

Hygiene programmers have established and adapted to the different needs within the manufacturing area.

Technical staff have Eyes examination annually through Health and Hygiene Department of Government of Balochistan.

Capsule Manufacturing

Preparation of Gelatin Solution.

After passing the preliminary quality control tests the Gelatin is released for production

Purified water is added in melter and then Gelatin is transferred by vacuum in the melter, and heated at 70 to 76 degrees centigrade until it reaches the correct viscosity, vacuum removes the air bubbles from solution

Here QA checked the viscosity and Temperature of Gelatin solution, Viscosity should be 25 to 27 inch and Temperature 55 to 58 degree centigrade

Color Mixing.

At this point natural Gelatin Solution is transferred in gelatin feed tanks of 80 & 120 Liter capacity and required colors & titanium di oxide is added for opaque and only colors are added for transparent capsules as per formulation of required shade,

Following Test are performed

Color Film preparation, Viscosity & Temperature of solution Gelatin Feed tanks hanged on Capsule manufacturing machine these machines are PLC controlled and capsule profile is programmed in machines, following manufacturing steps occurred

  • Dipping: Dipping of pin bars in gelatin solution. after dipping the pin bars are removed and rotated to distribute the gelatin as uniformly as possible around the pins than Gelatin allowed to set.
  • Drying of Capsule: Traveling along the conveyor belt, the bars carrying the pins coated with solidifies gelatin pass through a upper and lower kilns until the moisture content is reduced to required level.
  • Stripping, cutting and joining of shell: The machine automatically strips the formed Gelatin shells from the pins bars, Cut it to the correct length and join the cap and body in pre – closed position
  • Quality Assurance Capsules are hourly analyzed for physical defects, length, dome, Wall thickness, moisture content, weight, color shades other relevant parameters.

Capsules Imprinting

Gelcaps uses most modern Printing machines with two color inks, rectified axial and spin printing facility for unique and attractive identification of product as per customer requirement Corresponding quality control to check printing defects & Laboratory checks on Ink.

Capsule Sizes.

Empty hard gelatin capsules are used in various industries, particularly in pharmaceuticals and nutraceuticals, to encapsulate powders, granules, or liquids. Capsules come in various sizes to accommodate different dosages and formulation needs. The size of the capsule affects the amount of content it can hold and, consequently, the overall dosage of the product.

  1. Capsule Size Range
  • Size 0: A popular size for many applications, holding about 0.68 ml (680 mg) of powder.
  • Size 1: Holds approximately 0.50 ml (500 mg) of powder and is widely used for moderate doses.
  • Size 2: Holds about 0.37 ml (370 mg) of powder, suitable for smaller doses.
  • Size 3: Commonly used for smaller doses, holding approximately 0.30 ml (300 mg) of powder.
  • Size 4: Suitable for very small doses, holding around 0.21 ml (210 mg) of powder.
  1. Capsule Size Selection
  • Dosage Requirements: The size of the capsule should match the required dosage of the active ingredient. Larger capsules are used for higher doses, while smaller capsules are suitable for lower doses.
  • Formulation Type: The type of formulation (e.g., powder, granules, or liquid) affects the choice of capsule size. Certain formulations may require specific capsule sizes to ensure proper filling and functioning.
  • Patient Preferences: Smaller capsules may be preferred by patients who have difficulty swallowing larger capsules, especially in the case of dietary supplements and pediatric formulations.
  1. Special Capsule Sizes
  • Custom Sizes: Some manufacturers offer custom capsule sizes to meet specific needs or unique formulations. These capsules can be tailored to fit particular dosage requirements or to accommodate non-standard ingredients.
  • Double-Locking Capsules: Designed for high-value or sensitive ingredients, these capsules feature additional sealing mechanisms to ensure integrity and security of the contents.
  1. Materials and Coatings
  • Standard Gelatin: Typically made from bovine or porcine sources, providing a reliable and widely used option for encapsulation.
  • Vegetarian and Halal Options: Available for those with dietary restrictions, made from plant-based materials or complying with Halal standards.
  • Enteric Coatings: Specialized coatings that protect the contents from stomach acid and ensure the capsule dissolves in the intestines, often used for time-release or targeted delivery formulations.
  1. Quality Considerations
  • Consistency: Ensuring uniform capsule size and quality is crucial for accurate dosing and reliable performance.
  • Integrity: Capsules must maintain their structural integrity throughout handling and storage to ensure proper release of contents.