The Impact of Capsule Quality on Your Manufacturing Operation’s Profitability
How much does capsule quality impact the profitability of your capsule manufacturing operation? Quite a bit more than you might realize! Whether you’re using gelatin or HPMC capsules, if you want maximized output and minimized capsule defects, you need to start with high-quality capsules made to the exacting specs of your automatic filling machines.
Here are some of the many factors to consider…
Are the capsules made from high-quality raw material?
You might think that HPMC is HPMC, or all gelatin is the same. However, this is not the case. Just like with anything else, these materials come in a range of quality levels, and this quality is generally reflected in the capsule price. If a capsule provider’s low cost seems too good to be true, look closely at the quality of the raw material that is being used.
Is the capsule quality consistent from one lot to the next?
G-CAPS® gelatin capsules and K-CAPS® HPMC capsules, for example, which are both made in the Americas, are known for their consistency. You can count on getting the same precise, high-quality capsules, with the same precise dimensions and technical specs, with each order. This is not always the case with other capsule products.
Will you get an excellent capsule-to-tooling fit?
Having a precise capsule-to-tooling fit is vitally important for machinability and avoiding loss. If the capsules are just a tiny bit too big, they won’t seat properly in the tooling and they might fall out. If they’re a tiny bit too small, they’ll wobble and won’t separate or fill properly. Either way, things will run very poorly on your automatic filling machines, and problems will ensue.
Are they strong enough to hold up to the rigors of capsule filling?
A strong capsule shell will help you avoid a variety of common encapsulation problems. For example, robust construction helps ensure that the capsules won’t split or tuck if the edges of the capsule cap and capsule body collide during the joining process. It also helps avoid the problems with body and cap dents that are commonly experienced when weak capsules are used.
You should also be sure to look for gelatin or HPMC capsules with extra-strong domes on the capsule cap and body. This helps you avoid problems with pinholes and cracking, and ensures that if you need to push the limits on capsule filling and “overstuff” your capsules, the capsules will not break from the extra pressure.
Will the capsules separate well?
There’s nothing like capsules that don’t want to separate during capsule filling to drive your production staff crazy. The filling material is wasted, your machinery gets dirty and more down time is required to deal with these problems.
Look for capsules, such as K-CAPS® HPMC vegetarian capsules, which are known to separate well even at low suction levels. After all, if they’ll separate well at low suction levels, things will really be humming along at normal suction levels.
Will the capsules close properly?
If capsules are not sufficiently closed, they can come open before they reach the consumer. If they are over-closed, you’re likely to get dents and cracks.
The best way to ensure that your capsules are closing properly on your capsule filling machines is to use a capsule measuring tool that’s known as a “go/no go gauge.” This gauge will quickly show you if the capsule is properly closed, not locked or over-closed, so that you can make any adjustments necessary in real-time.
Will the capsule manufacturer provide technical services?
When questions arise, will there be a technical services team that you can call…or will you be on your own? As many manufacturers of pharmaceuticals and nutraceuticals have discovered, expert technical services and high-quality capsules go hand-in-hand.
Having the right gelatin or HPMC capsules, with excellent machinability, is the starting point. After that, there are myriad ways that technical services can increase your yields and reduce or eliminate inspections and rework. An expert technical services team can optimize (or even repair) your automatic filling machines, provide training to your staff members, and investigate and resolve a wide range of problems.
Conclusion
By reducing downtime and waste, high-quality capsules will have a significant positive impact on the profitability of your manufacturing operation by supporting higher yields, higher efficiency, and lower overall costs. The quality of your capsules really does make a significant difference. So when choosing capsules, choose wisely!