Tableting and encapsulation are essential processes in the manufacturing of dietary supplements. They allow active ingredients to be delivered and consumed in a convenient, precise dosage.
By combining deep expertise, meticulous attention to detail, and state-of-the-art equipment, high-quality tablets and capsules can be produced that maintain product bioavailability and efficacy.
Raw materials are painstakingly chosen based on desired characteristics and then blended to perfect homogeneity. The product can either be compressed into tablets or filled into two-piece capsules. The resulting dosage forms must meet strict specifications for weight variation, hardness, disintegration and dissolution to ensure they deliver the intended health benefits.
Experienced formulators carefully select just the right excipients like binders, disintegrants and flow agents, which produce an optimal finished product. With supplement usage on the rise, mastery of tabletting and encapsulation is more important than ever for brands that want to stand out and thrive in a saturated market.
When considering between tablets or capsules for your product, there are several factors to consider.
Tablets are regarded as more stable and have a longer shelf-life compared to capsules. Their toleration of environmental factors like heat, light and moisture is notable, making tablets easier to store and transport. They are generally cheaper to manufacture and package, and can be divided into smaller doses if required. Many patients find tablets smaller and easier to swallow than capsules.
Capsules provide a faster dissolution time than tablets, releasing their contents quicker into the body for rapid absorption and onset of action. Capsules can be manufactured to mask any unpleasant taste or odour of ingredients, whereas capsules require extra coatings to improve palatability. From a bioavailability perspective, capsules often enable more efficient absorption into the bloodstream of the active ingredients, rendering them more effective than tablets on average.
In choosing between tablets and capsules for your unique product, the decision will depend upon the specific formulation, required release profile, and target patient population. Both dosage forms have their own distinct benefits and drawbacks to carefully consider.
When it comes to supplement development, there are several types of capsules to choose from depending on the specific needs of the product.
Hard gelatine capsules are a popular choice, consisting of two halves that fit together to encapsulate powdered or granulated ingredients.
Soft gelatine capsules have a one-piece hermetically sealed shell that contains a liquid or semi-solid fill.
Enteric-coated capsules have a special polymer coating allowing them to pass through the stomach intact and release their contents in the intestines, ideal for ingredients that may be degraded by stomach acid or cause stomach irritation.
HPMC (hydroxypropyl methylcellulose) capsules are a vegetarian alternative to gelatine, made from plant-based ingredients. They have low moisture content and are suitable for hygroscopic ingredients.
Pullulan capsules, derived from fermented tapioca, offer another plant-based option that is preservative-free, gluten-free, and non-GMO.
Capsules in general provide many benefits as a delivery form, such as tasteless administration of unpleasant-tasting ingredients, fast-acting capabilities due to quick dissolution, and tamper-resistance compared to tablets. The choice of capsule type depends on factors like ingredient compatibility, desired release profile, and target consumer preferences.
At our state-of-the-art manufacturing facility, we specialise in advanced encapsulation technologies to optimise the performance and efficacy of your dietary supplements.
Our team of experienced formulators and production specialists employ cutting-edge techniques to protect sensitive active ingredients from degradation, ensuring their potency is maintained throughout the product’s shelf life.
We also excel at precision dosing, utilising strict quality control measures and advanced equipment to guarantee that each capsule contains the exact quantity of active compounds specified in your formula. Beyond ingredient protection and dosage accuracy, our encapsulation processes are designed to enhance the bioavailability of key nutrients, vitamins, and herbal extracts.
By selecting optimal encapsulation materials and release profiles tailored to each ingredient, we help maximize absorption in the body, allowing your customers to get the most out of your thoughtfully developed supplement formulas. With our extensive expertise and commitment to quality, you can trust us as your partner to deliver superior encapsulated products.
In our facility, we have several Bosch encapsulation machines which allow us to consistently provide top-quality encapsulation services. These impressive machines seamlessly combine precision engineering, cutting-edge technology, and user-friendly design to deliver consistent, reliable results with every batch.
The advanced features of our Bosch capsule fillers allow us to handle a wide range of capsule sizes and formulations, from delicate herbal blends to complex nutraceutical combinations. With customisable settings for fill weight, tamping force, and sealing parameters, we can fine-tune each machine to meet the specific needs of your unique product.
Built for both efficiency and durability, our Bosch machines run smoothly through long production cycles, ensuring timely completion of even the largest orders. Plus, the streamlined design makes changeovers between different capsule types a breeze, minimizing downtime and maximizing productivity.
When you choose our encapsulation services, you can trust that your capsules are in the capable hands of our skilled technicians and the unparalleled performance of our Bosch encapsulation machines.
Alongside our Bosch machines, our Semi Auto encapsulation machines give us a more hands-on approach to encapsulating your products. These machines provide a bit more manual control compared to fully automated solutions like our Bosch machines, while still streamlining the process and boosting your production efficiency.
With a semi-auto encapsulation machine, an operator manually feeds empty capsules into the machine, which then precisely fills them with your powder or liquid and seals them shut. It’s a great middle ground, giving you enhanced production capacity and consistency, yet still allowing for that personal touch and attention to detail.
In addition to the encapsulation machines, we also have capsule polishers. These machines are designed to gently polish and smooth the surface of capsules, giving them a professional and appealing appearance. The polishing process also helps remove any excess powder or debris that may be clinging to the capsules after filling.
Most capsule polishers work by tumbling the capsules in a rotating drum lined with a soft material like felt or cotton. As the capsules tumble, they gently rub against each other and the lining, which buffs and shines their surface to a glossy finish. Some models feature empty capsule reject systems that can detect and remove any unfilled or partially filled capsules, ensuring only perfect product makes it through.
With the ability to polish anywhere from 3,000 to 150,000 capsules per hour, these machines are very hard working and help us keep our capsule products looking sharp.
We have several NP400 tablet presses, versatile and reliable machines capable of efficiently producing high-quality tablets. These tablet presses allow us ample capacity to seamlessly handle both small and large production runs.
The NP400 features a robust design, intuitive controls, and precision engineering to accurately press a wide variety of tablet formulations with ease. It offers adjustable compression force and fill depth to fine-tune the tablet’s weight, hardness, and thickness to meet exact specifications.
Quick tooling changeovers let us rapidly switch between different tablet shapes and sizes to fulfil diverse customer needs. The machine’s cGMP-compliant construction, made with high-grade stainless steel, also enables easy cleaning and supports our rigorous quality and hygiene standards.
The NP400 can enable us to scale up production as required while maintaining consistency from tablet to tablet. These reliable, high-performance tablet presses are a key asset, helping us dependably deliver top-quality tablets to our valued customers.
Our facility is also equipped with a top-of-the-line Fette tablet press, a precision machine engineered for high-volume pharmaceutical tablet production. This impressive piece of equipment is designed to deliver exceptional performance, reliability, and tablet quality. The press can produce tablets of various shapes and sizes with outstanding consistency and accuracy. The machine’s modular design also allows for quick changeovers, enhancing production flexibility.
Fette is a trusted name in the industry, known for crafting tablet presses that combine innovation, efficiency, and unwavering German engineering. With this Fette tablet press as part of our manufacturing line, we can produce premium-quality tablets while meeting the most demanding production requirements.
Our robust tablet coating machines can effortlessly handle high-volume production. Our smaller unit has an impressive capacity range of between 40 to 75 kilos per batch, whilst for larger batches our second unit can output a capacity range of 75 to 150 kilos.
Operated by skilled technicians, these machines are designed to deliver consistent, high-quality coatings across a variety of tablet sizes and shapes. The coating process itself involves gently tumbling the tablets in the rotating drum as the coating solution is sprayed on. As the coating builds up layer by layer, the tablets take on a smooth, polished finish that protects the active ingredients and controls their release in the body. Batch after batch, you will be satisfied with the finished product.
Our minimum order quantities (MOQs) are designed to be as flexible as possible allowing us to meet your unique requirements. We understand each project is different and therefore we do not impose rigid minimum order restrictions, instead preferring to enthusiastically work with you to fulfil your request.
We will consider the specifics of your product, including the size and type of tablet/capsule, the ingredients in the formulation, and our current manufacturing capacity and schedule. After taking all factors into account, we will strive to establish MOQs that suit your timeline and budget.
At Wasdell, we pride ourselves on our commitment to our customers, so we encourage you to discuss your project with our knowledgeable and friendly team and to allow us to find a cost-effective, efficient and high-quality solution to your requirements.
