R&D Softgel Encapsulation Machine | Laboratory Scale Soft Gel Capsule Filling Equipment
Overview
The Vitol R&D softgel encapsulation machine is a compact, precision-engineered rolling-mode softgel encapsulation machine designed specifically for pharmaceutical R&D laboratories, formulation development teams, and regulatory submission batch production. This benchtop soft gelatin capsule machine enables manufacturers to produce both gelatin-based and starch-based soft capsules without requiring any die or component changeover, delivering exceptional versatility for new product development and clinical trial material manufacturing.
As a laboratory-scale softgel encapsulator, the R&D softgel encapsulation machine addresses a critical need in the pharmaceutical and nutraceutical industries: the ability to generate representative production samples at small batch sizes while maintaining the fill accuracy and process consistency required for regulatory filings with FDA, EMA, and ASEAN authorities. The integrated system combines gelatin ribbon formation, precise fill dosing, hermetic sealing, and capsule shaping in a single continuous process, mirroring the performance of full-scale production softgel machines on a reduced footprint.
Key Technical Specifications
|
Parameter |
Specification |
|
Mold |
VIT2 |
|
Die Rotation Speed |
1 – 3.5 rpm (variable speed control) |
|
Die Dimensions |
Φ150 mm × 50 mm |
|
Fill Volume Accuracy |
1.5 mL fill volume at ±1.5% deviation |
|
Theoretical Output (8# Oval) |
6,120 capsules/hour @ 1.5 rpm |
|
Theoretical Output (20# Oblong) |
2,970 capsules/hour @ 1.5 rpm |
|
Main Spindle Support |
Precision bearing assembly |
|
Gelatin Roller Cooling |
External recirculating chiller system |
|
Roller Lubrication System |
Micro-precision lubrication pump |
|
Fill Pump Lubrication |
Diaphragm pump external circulation |
|
Gelatin Roller Material |
Chrome-plated stainless steel (pharma-grade) |
|
Combined Power Consumption |
Approx. 2 kW (main unit + tumble dryer) |
|
Shell Material Compatibility |
Gelatin & starch (no changeover parts required) |
Core Technology & Design Features
Precision Die Alignment Mechanism
The VIT2 softgel filling machine incorporates a precision linkage die alignment system that performs both initial die registration and fine accuracy adjustment during operation. This patented alignment architecture ensures consistent web registration between the two rotary die rolls, directly contributing to the machine's industry-leading ±1.5% fill weight accuracy at 1.5 mL dosage volumes. The system supports single-operator adjustment with real-time online fine-tuning capability, eliminating the need for production stoppages during parameter optimization.
Micro-Precision Lubrication System
Unlike conventional softgel capsule machines that rely on manual or gravity-fed lubrication, the R&D softgel encapsulation machine employs electromagnetic metering technology to deliver ultra-fine lubricant application to the gelatin rollers. The precision-controlled lubrication system ensures uniform oil film distribution across the roller surface, preventing capsule sticking while minimizing lubricant carryover onto finished softgels-a critical consideration for pharmaceutical products where residual lubricant could impact downstream coating or packaging processes.
Intelligent Gelatin Delivery & Level Control
The gelatin supply system integrates advanced level sensors with pneumatic valve control architecture to achieve automatic gelatin level detection and precise flow regulation. This closed-loop gelatin management system maintains consistent ribbon thickness and viscosity throughout the production run, directly improving capsule seam integrity and reducing reject rates. The stable level control also minimizes operator intervention, supporting extended unattended operation during clinical batch production.
Modular Conveyor & Drying Integration
The integrated capsule conveyor system features a lightweight, space-efficient design engineered for rapid disassembly and thorough cleaning-essential for cGMP compliance and multi-product manufacturing environments. The conveyor transfers freshly encapsulated softgels directly to the integrated tumble drying unit, initiating the initial drying phase immediately after encapsulation to preserve capsule shape and dimensional consistency. All product-contact surfaces are constructed from pharmaceutical-grade stainless steel with smooth, crevice-free finishes to facilitate effective cleaning validation.
Capsule Format Versatility
The VIT2 rotary die softgel machine supports a comprehensive range of capsule shapes and sizes, enabling formulation scientists to evaluate multiple dosage form options during product development.
Specialty & Custom Shapes
Beyond standard oval and oblong formats, the VIT2 softgel encapsulation machine can produce custom and novelty-shaped soft capsules for pediatric formulations, veterinary products, and branded consumer health applications. Custom die tooling is available to support product differentiation and intellectual property protection.
Pharmaceutical & Regulatory Compliance
Designed with global pharmaceutical manufacturing requirements in mind, the VIT2 soft gelatin capsule machine supports compliance with cGMP (current Good Manufacturing Practices) regulations across the United States, European Union, and Southeast Asian markets including Thailand, Indonesia, Vietnam, Malaysia, and the Philippines.
Materials of Construction
All product-contact surfaces are fabricated from pharmaceutical-grade stainless steel with polished finishes suitable for clean-in-place (CIP) protocols and cleaning validation procedures. The chrome-plated gelatin rollers provide a hard, non-reactive surface that maintains dimensional stability across repeated production and sanitation cycles.
Process Control & Data Integrity
The PLC-based control system with HMI touchscreen interface enables operators to set, monitor, and record critical process parameters including die speed, gelatin temperature, and fill pump settings. Electronic parameter recording supports batch documentation requirements and aligns with data integrity principles (ALCOA+) expected by regulatory inspectors during GMP audits.
Validation Support
Equipment documentation packages are available to support Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ) validation activities required for pharmaceutical facility qualification. The consistent performance and reproducible output of the VIT2 make it suitable for generating stability batches, clinical trial materials, and regulatory submission batches.
Industry Applications
Pharmaceutical Manufacturing
The VIT2 softgel encapsulation machine serves pharmaceutical companies developing lipid-based drug delivery systems, self-emulsifying drug delivery systems (SEDDS), and poorly soluble API formulations. The machine's precision fill accuracy supports bioavailability studies and clinical trial material production for both oral and topical softgel dosage forms.
Nutraceutical & Dietary Supplement
For health supplement manufacturers, the machine supports production of fish oil softgels, vitamin E capsules, omega-3 formulations, probiotic softgels, and herbal extract products. The dual gelatin/starch compatibility enables manufacturers to develop both traditional gelatin and vegetarian/vegan softgel product lines.
Cosmeceutical & Personal Care
The encapsulation technology also applies to cosmetic and personal care formulations including serum capsules, essential oil softgels, and topical treatment delivery systems where hermetic sealing preserves ingredient potency and shelf stability.
Why Choose The VIT2 Laboratory Softgel Encapsulator
The VIT2 rolling-mode soft capsule machine fills a unique position in the global softgel equipment market as a dedicated R&D and small-batch production system that delivers production-grade accuracy at laboratory scale. For pharmaceutical companies in North America, Europe, and Southeast Asia seeking to accelerate formulation development while maintaining regulatory readiness, the VIT2 offers several distinct advantages:
- Dual shell material capability - produce both gelatin and plant-based starch softgels without mechanical reconfiguration, reducing development time for vegetarian formulation projects
- Superior fill accuracy - ±1.5% fill weight deviation meets pharmaceutical dosage uniformity requirements for clinical trial materials
- Low energy footprint - approximately 2 kW combined power consumption minimizes facility infrastructure requirements for pilot plants and R&D laboratories
- Single-operator design - intuitive controls and online adjustment capability reduce labor requirements during formulation development runs
- cGMP-ready construction - stainless steel product contact surfaces and cleanable design support GMP compliance for pharmaceutical and nutraceutical manufacturing facilities
- Scalable process technology - rotary die encapsulation principles match full-scale production machines, simplifying technology transfer from lab to manufacturing scale
Technical Support & After-Sales Service
Vitol provides comprehensive technical support for VIT2 softgel encapsulation machine installations worldwide, including factory acceptance testing (FAT), on-site installation commissioning, operator training programs, and ongoing spare parts supply. Our international service network supports customers across the United States, EU member states, and Southeast Asian pharmaceutical manufacturing hubs with responsive technical assistance and application engineering support.
For pharmaceutical companies, contract development and manufacturing organizations (CDMOs), and nutraceutical producers evaluating softgel encapsulation equipment for R&D or small-batch production, the VIT2 rotary die softgel machine delivers proven encapsulation technology in a compact, regulatory-compliant platform.
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