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Softgel Manufacturing for Custom Supplements

Develop custom and private label softgels from formula review to finished packaging. Botanovance reviews your fill, shell and dose requirements, coordinates production through its manufacturing network and supplies project documentation such as specifications and batch COAs.
Share your formula, target dose and order quantity to check feasibility and request a quotation.

What Softgels Are Best Suited For

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A softgel is a one-piece, sealed capsule that holds a liquid or semi-solid fill. It suits oils, oil-soluble nutrients and actives that can be dissolved or suspended in a carrier oil.
Fill type Common examples
Oils Fish oil, krill oil, algal oil, flaxseed oil, evening primrose oil
Oil-soluble nutrients Vitamins A, D3, E and K2, CoQ10, lutein, astaxanthin
Suspensions Powders or extracts dispersed in oil with a suspending agent such as beeswax
Botanical extracts Oil-soluble extracts, or suspended standardized extract grades after compatibility review
Fills with high water content, extreme pH or reactive compounds such as aldehydes can damage or harden the shell. These formulas may need reformulation or a different dosage form, such as capsules or tablets.

Softgel Specifications That Shape Your Product

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The formula, carrier and shell must work together during manufacturing and storage. We review these requirements before confirming available production options.
Requirement Details to specify
Formula Ingredients, concentrations and proposed carrier oil
Dose Active amount per softgel and softgels per serving
Fill and size Total fill weight, preferred shape (round, oval or oblong) and acceptable size
Shell Gelatin source or plant-based shell, color, transparency and any halal, kosher or vegan requirement
Release Standard release or enteric (delayed-release) requirement
Packaging Bulk or retail packs, count per pack and destination market
Specify active dose separately from total fill weight. Carrier oil and suspending agents add to the fill weight. For example, a 100 mg CoQ10 softgel may need several hundred milligrams of total fill, which sets the capsule size.

Gelatin and Plant-Based Softgel Shells

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A softgel shell is made from gelatin or a plant-based polymer, combined with a plasticizer such as glycerin or sorbitol. The right shell depends on your fill, label claims and target market.
Shell type Typical use Points to confirm
Bovine gelatin Most general supplement fills Source and halal or kosher certification, if required
Porcine gelatin General supplement fills Not suitable for halal, kosher or vegetarian claims
Fish gelatin Marine or pescatarian positioning Fish allergen labeling may apply in your market
Plant-based (e.g. modified starch and carrageenan) Vegetarian and vegan products Fill compatibility and size options can differ from gelatin
State shell and certification requirements at the start, as they affect supplier selection, MOQ and lead time.

From Formula Review to Softgel Production

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Softgel contract manufacturing starts with a workable product specification. Each project moves through three stages:
  • Feasibility review: Assess ingredient suitability, fill characteristics, shell compatibility and target dose.
  • Sample and specification approval: Agree on available sample or trial work, product requirements and acceptance criteria.
  • Production and delivery: Confirm manufacturing, packaging, release documentation and shipping arrangements.
In production, the fill and the shell gel mass are prepared separately. On a rotary die machine, two shell ribbons are formed and sealed around a measured dose of fill. Softgels are then dried to the target shell hardness, inspected, sorted and packed.
For an existing product, share the current specification and any testing or stability records. If the formula is still in development, see supplement formulation development.

Quality Checks for Finished Softgels

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The quality review covers both the fill content and the capsule’s performance. Testing scope, methods and acceptance limits are agreed for each formulation and target market.
Review area Key considerations
Fill quality Active content, fill weight and uniformity between softgels
Shell and seal Seal integrity, leakage, sticking, deformation and appearance
Release performance Disintegration or rupture testing; shell hardening during storage can slow release
Stability Changes in active content, oxidation of oil fills and physical changes over shelf life
Contaminants Microbial limits, heavy metals and other limits set for the destination market
Packaging Protection from moisture, heat, light and oxygen suited to the formula
Available documentation may include specifications, batch COAs, analytical methods and stability records. Certification scope is confirmed for the manufacturing site and product. Learn more about analytical testing, certifications and regulatory documentation support.

MOQ, Pricing and Production Lead Time

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MOQ, pricing and lead time depend on the confirmed formula, shell, batch size, testing and packaging. Custom shell colors, uncommon sizes or plant-based shells can affect all three.
For a comparable quotation, specify:
  • Quantity: Initial order and expected repeat demand.
  • Scope: Development, testing, bulk softgels or finished retail packs.
  • Timing: Required launch date and delivery destination.
The quotation should separate development charges from production costs and state whether the schedule ends at dispatch or at delivery.

Softgel Manufacturing FAQs

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Yes. We support private label softgel projects covering formula requirements, manufacturing and packaging coordination. Existing formula availability and labeling support are confirmed for each product. See private label supplements for the full service.

Fish and plant oils, fat-soluble vitamins such as D3, E and K2, CoQ10, lutein and astaxanthin are common softgel fills. Powders can also be used when suspended in a carrier oil.

Some can, but suitability depends on the extract grade, concentration, carrier and shell compatibility. A standard powder specification does not confirm softgel suitability.

Yes. State the requirement at the start so a plant-based shell system can be checked. Vegan suitability requires review of the complete formula, including the fill and all other components.

Softgels suit compatible liquid or semi-solid fills. Hard capsules commonly hold powders, granules or pellets, although liquid-filled hard capsules also exist. Formula characteristics, dose and shell preferences guide the choice; see capsule manufacturing.

Share the formula, active dose per softgel, shell preference, order quantity, packaging format and destination market. Existing specifications or test records speed up the review.