Direct factory wholesale ingredients and contract softgel encapsulation solutions tailored for global nutraceutical and pharmaceutical brands.
High-viscoelasticity natural wheat protein binder for specialty matrix texturizing and nutritional fortification.
Advanced cyclic oligosaccharide designed for molecular encapsulation of lipophilic actives in liquid softgels.
Pure non-GMO fermented soy base featuring rich natural amino acid profiles for functional food formulations.
High-lycopene organic tomato concentrate ideal as a natural antioxidant extract source for wellness blends.
Nutrient-dense hydrolyzed yeast powder packed with natural B-vitamins, nucleotides, and bioavailable peptides.
Controlled DE value starch derivative serving as a premium carrier for spray-dried softgel fill suspension powders.
Nitrate-rich dehydrated botanical extract supporting cardiovascular health and metabolic softgel formulations.
High-purity skin-brightening active optimized for cosmeceutical softgel capsules and topical liquid pearls.
In the rapidly evolving landscape of dietary supplements and pharmaceutical delivery systems, soft gelatin capsules (softgels) stand out as the gold standard for delivering hydrophobic nutrients, lipophilic active pharmaceutical ingredients (APIs), and complex botanical extracts. Modern procurement teams face strict challenges regarding batch-to-batch uniformity, seam integrity, oxidative stability, and regulatory compliance. Partnering with an experienced, certified bulk softgels factory is paramount to securing global market access.
Zeon Lifesciences Ltd, established in 1987, brings over 38 years of specialized formulation experience to contract research and manufacturing services (CRAMS). Operating from US FDA-registered and FSSC 22000-certified facilities in Paonta Sahib, Himachal Pradesh, Zeon merges advanced gelatin ribbon technology with rigorous analytical testing to supply over 60 international markets.
Our softgel encapsulation lines integrate continuous micro-dosing pumps, precision rotary dies, and climate-controlled drying tunnels (20–22°C with RH < 20%) to prevent cross-linking and ensure predictable gelatin disintegration profiles. Whether your brand requires bovine, porcine, or plant-based vegetarian softgel shells (Tapioca/Pectin), our manufacturing infrastructure ensures optimal shell elasticity (Bloom strength 150–200) and fill weight precision (+/- 1.5%).
Fully compliant production blocks audited by Intertek, US FDA, FSSAI, AYUSH, and Halal boards to guarantee audit-ready documentation packs for global distribution.
Specialized nitrogen-blanketing blending tanks protect sensitive Omega-3s, CoQ10, Astaxanthin, and Vitamin D3/K2 oil suspensions from thermo-oxidative degradation.
In-house analytical testing using HPLC, Gas Chromatography (GC), UV-Vis Spectrophotometry, and Dissolution apparatus to validate active potencies and shelf-life stability.
As consumer preferences shift toward clean-label and higher bioavailability formats, softgel manufacturing is undergoing significant technological evolution. B2B buyers must align with factories capable of implementing next-generation encapsulation innovations:
| Technological Trend | Technical Challenge | Zeon Advanced Solution | Commercial Advantage |
|---|---|---|---|
| Plant-Based Vegan Softgels | Gelatin alternatives suffer from high seal temperatures and ribbon stickiness. | Modified Tapioca Starch + Carrageenan dual-polymer matrix with low thermal hysteresis. | Unlocks Vegan, Kosher, and Halal consumer markets with zero animal derivatives. |
| Enteric Targeted Release | Gastric acid damages delicate enzymes and causes unpleasant reflux (e.g., fish oil). | In-line shell polymer modification for pH-dependent enteric protection (USP <701>). | Eliminates fishy burps, protecting acid-sensitive probiotics and botanical actives. |
| Self-Emulsifying (SEDDS) | Poor intestinal absorption of hydrophobic actives (Curcumin, Resveratrol). | Micro-emulsion lipid vehicle engineering that forms nanometer droplets upon gut contact. | Up to 300% higher bioavailability with lower active ingredient dosage requirement. |
| Chewable Softgels | Hard shell texture and bitter active taste masking for pediatric/geriatric use. | Glycerin-rich shell formulations with proprietary natural flavor and sweetener systems. | Higher patient compliance for pediatric Omega-3 and multi-vitamin supplementation. |
1. Strict Oxidation Limits (TOTOX Controls): Global brand owners are enforcing maximum Peroxide Value (PV < 5 mEq/kg) and Anisidine Value (AV < 20) benchmarks. Our factory implements nitrogen sparging throughout oil receiving, batch blending, and die encapsulation to guarantee low TOTOX ratings.
2. Regulatory Dossier Readiness (CTD/ACTD): Overseas buyers now require comprehensive stability data under ICH guidelines (Zone IVb conditions: 30°C/75% RH). Zeon provides complete stability protocol reports, allergen declarations, and Free Sale Certificates (FSC) for fast registration.
From initial concept screening and benchtop formulation to pilot trials and high-speed commercial packaging, our single-source model minimizes development risk and reduces time-to-market.
Blister packaging (Alu-Alu, PVC/PVDC), HDPE bottles, glass jars, and secondary carton assembly with tamper-evident induction sealing and serial barcode printing.
Comprehensive inventory of dies ranging from 3 Oval, 10 Oval, 20 Oblong, to 7.5 Round, plus custom logos engraved directly onto softgel capsules.
Strict vendor qualification protocols. Every batch of fish oil, botanical powder, and gelatin undergoes raw material identity verification via FTIR and heavy metal testing via ICP-MS.
Clear, technical answers to common questions asked by B2B buyers, quality managers, and supplement brand owners.
Our standard bulk softgel encapsulation MOQ starts at 300,000 capsules per production run depending on die size, shell type (gelatin vs. vegetarian), and fill active complexity. For specialty custom formulations, pilot scale runs can be discussed with our technical team.
Leakage prevention is ensured through strict rib tension control, precise ribbon thickness monitoring (+/- 0.02 mm), continuous seam integrity inspection under high-magnification optics, and controlled tumble drying to achieve target shell moisture content (6%–8%).
Our manufacturing campus operates under US FDA registration, Intertek FSSC 22000, WHO-GMP, HACCP, ISO 22000, FSSAI, AYUSH (for botanical lines), and Halal certifications. We supply full technical documentation packs including Certificate of Analysis (COA), BSE/TSE-Free statements, and stability studies.
Yes. Our in-house R&D team of over 50 scientists specializes in solubilizing hard-to-dissolve powders into stable oil suspensions, utilizing self-emulsifying carrier matrices, liposomal delivery systems, and natural surfactant blends to maximize bioavailability.
We offer premium 150-200 Bloom bovine bone gelatin, porcine gelatin, pharmaceutical-grade fish gelatin (for pescatarian brands), and advanced non-GMO plant-based polymers (tapioca starch combined with carrageenan/pectin) for vegetarian lines.
Initial formulation development and laboratory pilot batches require 2 to 4 weeks. Commercial production runs—including raw material assaying, encapsulation, drying, QC release, and primary packaging—are typically completed within 4 to 6 weeks.
Connect directly with our technical sales engineers and formulation scientists to request product specifications, custom bulk quotations, and technical dossiers.
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