Wuxi Jangli Machinery Co., Ltd.

IntroductionIn today's globalized industrial landscape, distance is no longer a barrier to quality assurance. We are proud to announce a major milestone in our partnership with a valued client from Russia: the successful completion of their Factory Acceptance Test (FAT). While traditional FATs involve on-site visits, this project stood out as a testament to modern engineering and digital collaboration—we executed the entire acceptance process remotely via video conferencing. From initial design to final approval, our team worked closely with the Russian client to ensure every technical specification was met. Despite the geographical distance (over 4,000 miles separating our facilities), we delivered a seamless, transparent, and thorough testing experience. The result? A fully approved production line, now ready for shipment and tailored precisely to our client's operational requirements. A New Standard for Remote TestingThe remote FAT was structured to provide our client with complete visibility and control over the testing process, as if they were standing right beside our engineers on the factory floor. Over the course of two intensive video sessions, we live-streamed every critical test procedure. Our engineers used high-definition cameras to zoom in on mechanical movements, electrical connections, and safety protocols. The client's team asked questions in real-time, requested specific machine operations, and verified performance data through shared screens. This interactive approach not only saved time and travel costs but also accelerated the decision-making process. Tailored Solutions: The Russian-Language PLC InterfaceOne of the most significant aspects of this project was the depth of customization we delivered. Recognizing that our client's operators need to work with intuitive, error-free controls, we developed a fully localized PLC (Programmable Logic Controller) interface in Russian. This level of personalization ensures that our client can deploy the line immediately upon arrival, with minimal training and maximum productivity from day one. What Comes NextWith the FAT successfully passed, the equipment is now undergoing final packaging and preparation for international shipment. Our logistics team is coordinating with freight forwarders to ensure safe and timely delivery to Russia. Our commitment, however, does not end with delivery. We will provide remote installation support, video-based training, and ongoing technical assistance to ensure our client's production runs smoothly for years to come. Your Project, Your WayThis project proves that we can deliver high-quality, customized industrial solutions to any corner of the world. Whether you need a specific language interface, special safety features, or a completely bespoke production line, we are ready to listen and adapt. Just share your requirements with us, and we will customize the line for your project. No matter the challenge, we bring the same dedication, precision, and collaborative spirit to every partnership.

Softgel capsules are trusted for their excellent bioavailability and consumer appeal, but encapsulating powdered ingredients has traditionally been a challenge. Today, advanced formulation technologies are changing that. A range of proven techniques now enables manufacturers to convert solid actives into stable, bioavailable liquid fills—without compromising shell integrity or production efficiency. Bridging the Gap: Transforming Powders into Fillable FormatsTo make a powder compatible with the softgel encapsulation process, it must first be transformed into a flowable, homogeneous matrix. The choice of approach depends on the physicochemical properties of the active ingredient, particularly its solubility, stability, and particle behavior. Lipid-Based SuspensionsThe most common and straightforward method involves dispersing micronized powder into a lipid vehicle, such as medium-chain triglycerides (MCT), vegetable oils, or non-ionic surfactants. This approach works exceptionally well for oil-soluble nutrients and botanical extracts, offering both chemical protection and a ready-to-absorb medium. Solubilization in Approved SolventsFor actives that exhibit true solubility in either lipophilic or hydrophilic solvents, dissolution prior to filling eliminates particulate settling and ensures dose uniformity. This technique is frequently applied to coenzyme Q10 and various synthetic pharmaceutical intermediates. Self-Emulsifying Drug Delivery Systems (SEDDS)When dealing with highly lipophilic or poorly water-soluble compounds, SEDDS technology offers a breakthrough. By blending the powder with oils, emulsifiers, and co-solvents, formulators create a concentrate that spontaneously forms fine oil-in-water emulsions upon gastric mixing—dramatically enhancing dissolution and systemic uptake, as seen with curcumin and resveratrol formulations. Micro- and Nano-Encapsulation Pre-TreatmentA more sophisticated route involves pre-encapsulating the powder itself into microscopic polymer or lipid spheres. These pre-processed particles are then suspended in the softgel fill, adding an extra layer of protection against degradation while enabling tailored release kinetics. Cyclodextrin Inclusion ComplexesFor actives plagued by extreme hydrophobicity, complexation with cyclodextrins modifies the molecular environment, temporarily shielding hydrophobic moieties and improving apparent solubility in aqueous gastrointestinal fluids. Why Choose Softgels for Powder-Derived Formulations? Superior Protection – The hermetic seal of the softgel shell, combined with carefully selected fill excipients, guards oxygen- and moisture-sensitive compounds throughout shelf life. Flexible Release Design – By adjusting the fill matrix or employing coated beadlets, formulators can achieve immediate, sustained, or delayed release from a single dosage unit. Consumer Preference – Softgels are inherently easier to swallow and often perceived as more premium than traditional tablets or two-piece hard capsules. Navigating the Formulation ChallengesDespite the benefits, powder-to-softgel conversion is not without its hurdles. Equipment manufacturers and formulators must work in tandem to address: Matrix Compatibility – The chosen carrier must remain chemically inert with the active, avoiding degradation or crystal growth over time. Shell Integrity – Certain solvents or surfactants can migrate into the gelatin or plant-based shell, causing brittleness or softening. Compatibility testing with both gelatin and HPMC (hydroxypropyl methylcellulose) alternatives is essential. Processing Parameters – Maintaining homogeneous dispersion during high-speed filling demands precise temperature control, mixing protocols, and deaeration systems. Viscosity fluctuations can directly impact fill weight accuracy and sealing quality. The Role of Advanced Manufacturing EquipmentModern softgel encapsulation lines are increasingly equipped with features tailored to handle non-Newtonian and thixotropic fills. From jacketed hoppers to variable-speed homogenizers, the machinery must accommodate a wide viscosity range while ensuring minimal air entrapment. Moreover, real-time density monitoring and servo-driven injection systems have become critical for achieving the ±2% fill-weight tolerances expected in commercial production. As consumer demand shifts toward plant-based shells and clean-label ingredients, equipment flexibility—particularly the ability to process both gelatin and thermoreversible vegan polymers—has moved from a nice-to-have to a non-negotiable requirement. JANGLI is a global leader in softgel encapsulation technology, providing integrated solutions from R&D support to high-speed production systems. With decades of expertise in liquid and semi-solid filling, we empower customers to bring innovative, high-quality softgel products to market with confidence.

How to Select the Right Gelatin for Softgel Manufacturing Selecting the right gelatin is one of the most critical decisions in softgel manufacturing. The quality and characteristics of gelatin directly determine capsule integrity, stability, production efficiency, and ultimately, the bioavailability of the active ingredients. A poorly chosen gelatin can lead to leakage, brittleness, poor sealing, inconsistent dissolution, and costly production delays. This guide outlines the key factors to consider when sourcing gelatin for your softgel production. 1. Understand Gelatin Types: Type A vs. Type B Gelatin is classified into two main types based on the manufacturing process, each with distinct properties: Type A Gelatin – Produced through an acid pretreatment process, primarily from porcine skin or connective tissue. It has a lower pH and generally lower viscosity compared to Type B. Type A is commonly used in applications requiring clarity and faster setting. Type B Gelatin – Produced through an alkaline (lime) pretreatment process, mainly from bovine hides or bones. It has a higher pH, higher viscosity, and produces stronger gels with less leakage. The processing time is significantly longer—up to several weeks. Property Type A Type B Raw Material Primarily porcine skin Bovine hides or bones Extraction Method Mild acid pretreatment Alkaline (lime) pretreatment pH Low (acidic) High (alkaline) Viscosity Lower Higher Processing Time Shorter (days to a week) Longer (up to weeks) Both types are used in softgel manufacturing, and in many cases, a blend of Type A and Type B gelatin can be used to achieve the desired balance of properties. 2. Evaluate Key Specifications Bloom Strength (Gel Strength) Bloom strength measures the firmness of the gelatin gel and is a critical parameter for softgel performance. For softgel capsules, medium Bloom gelatins—typically in the range of 150–200 grams—are commonly used. Higher Bloom values result in firmer capsules, while lower values produce more flexible shells. The right Bloom strength depends on the target capsule characteristics, fill formulation, and process requirements. Viscosity Viscosity affects the flow behavior of the gel mass and its film-forming properties. Gelatin with appropriate viscosity ensures smooth ribbon formation, proper sealing, and consistent fill weight. Studies show that gelatin types with higher molecular weight and viscosity form seals less readily, increasing the risk of leakage and poorly shaped softgels. For softgel applications, selecting a gelatin with balanced viscosity—typically with viscosity below about 4.2 mPa·s for certain formulations—is essential for defect-free production. PH PH affects the stability and compatibility of the gelatin with the fill formulation. Both Type A and Type B gelatins are used in softgel manufacturing, and the choice often depends on the specific requirements of the active ingredient and fill composition. 3. Consider Source Material and Consumer Preferences Gelatin sources include bovine, porcine, and fish. Each source carries different considerations: Bovine Gelatin – Widely used, with strong and durable consistency. Requires TSE/BSE documentation verifying species and geographic origin. Porcine Gelatin – Offers excellent gelling properties and smooth texture. The preferred choice for many applications, though market considerations may apply. Fish Gelatin – Suitable for Halal, Kosher, and certain dietary preference markets. Offers a lighter, more flexible alternative with lower Bloom values (typically 160–200 Bloom) and different gel point characteristics. Vegetarian/Plant-Based Alternatives – Made from starch, carrageenan, pullulan, or pectin, these address the growing vegan and clean-label market segments, though they come with different processing requirements and performance characteristics. 4. Regulatory and Supplier Qualification Sourcing pharmaceutical-grade gelatin requires rigorous supplier qualification. A compliant gelatin supplier should provide: Certificate of Analysis (CoA) – Lot-specific values for Bloom strength, viscosity, moisture, pH, heavy metals, and microbiological quality. TSE/BSE Declaration – For bovine and porcine gelatin, confirming species, geographic origin, and compliance with relevant regulations. Country-of-Origin Certificate – Verifies raw material sourcing for traceability and regulatory submissions. Allergen Declaration – Formal statement confirming allergen status under relevant regulations. Current Certifications – Look for GMP compliance, ISO 9001, ISO 22000, and relevant industry certifications. For pharmaceutical applications, suppliers should meet standards aligned with regulatory expectations. 5. Assess Functional Properties for Your Specific Formulation The ideal gelatin for one product may be unsuitable for another. Key functional properties to evaluate include: Film-Forming Capability – The gelatin must produce films with appropriate mechanical strength, elasticity, and uniformity for reliable capsule formation and sealing. Solubility and Dissolution – The gelatin shell must dissolve efficiently in the gastrointestinal tract to ensure proper release of active ingredients. Cross-Linking Resistance – Certain fill formulations containing reactive components (e.g., aldehydes, certain lipids) can cause gelatin cross-linking during storage, leading to tough, insoluble shells. Gelatin with the correct molecular weight distribution can help mitigate this risk. Foaming Control – Gelatin with reduced foaming properties increases the amount of gel mass that can be prepared efficiently and reduces deaeration time and costs. Conclusion Selecting the right gelatin for softgel manufacturing is a multi-dimensional decision that requires balancing technical specifications, regulatory compliance, source considerations, and formulation-specific performance requirements. Partnering with a reputable supplier who can provide comprehensive documentation, technical support, and consistent quality is essential for successful production. A well-chosen gelatin not only ensures defect-free capsules but also enhances production efficiency and product stability throughout the shelf life.

Softgel encapsulation machines are core equipment in the pharmaceutical and nutraceutical industries. Their operational stability directly affects product quality and production efficiency. Compared with reactive repair after failure, a scientific preventive maintenance program can identify potential issues in advance, reduce unplanned downtime, and lower operating costs—making it the key to extending equipment service life. Based on the machine's structural features and actual production practices, this article outlines a comprehensive preventive maintenance plan, defining maintenance focus areas, frequencies, and standards to ensure long-term stable operation. I. Preventive Maintenance for Core Components Roll MoldsMolds are critical for capsule forming. After each production shift, wipe the mold surfaces with a cleaner to remove residual material and oil. Check clearance and parallelism weekly; adjust or replace if deviation or wear is found. Apply rust preventive treatment monthly, and store molds in a dry environment with rust-proof oil when not in use. Feeding SystemIncludes hopper, feed pump, and pipelines. Clean the inner hopper surface daily. Check pump seal integrity and operation weekly, and replace aged seals. Flush pipelines monthly to remove residual material and ensure smooth feeding. Drive SystemComprises motor, gears, and belts. Check motor temperature and noise weekly, and verify proper grounding. Inspect gearbox oil level and clean surface contamination monthly; replace deteriorated oil as needed. Adjust belt tension and replace worn/cracked belts quarterly to maintain stable power transmission. Lubrication SystemTop up lubricating oil at all lubrication points before daily start-up. Clean lubrication lines monthly to prevent blockage. Inspect and replace degraded oil semi-annually; never mix different oil grades. II. Preventive Maintenance Schedules Daily MaintenanceClean external surfaces, roll molds, and hoppers. Check power supply, air pressure, and lubrication points. Record operating status and address minor irregularities promptly. Periodic Maintenance (Weekly/Monthly)Weekly: check mold clearance, feed pump, and belt tension. Monthly: inspect lubrication and drive systems, flush pipelines, apply rust protection, and calibrate parameters. Quarterly OverhaulComprehensively inspect wear and aging components; replace consumables (seals, filters, etc.). Perform full cleaning, debugging, and calibration of encapsulation accuracy. Annual OverhaulEngage qualified professionals to disassemble and inspect the machine. Replace heavily worn core parts (molds, motor, gears, etc.). Check the structural integrity and electrical system. Conduct no-load and load tests before resuming production. III. Key Requirements and Precautions PersonnelMaintenance must be performed by trained personnel familiar with the equipment and procedures. Unauthorized disassembly or modification is strictly prohibited. SafetyCut off power and air supply before maintenance and post warning signs. Disinfect parts that contact materials. Use personal protective equipment when handling lubricants and cleaning agents. DocumentationEstablish a maintenance logbook recording date, actions, replaced parts, and machine status, enabling traceability and optimized maintenance planning. EnvironmentMaintain a dry, well-ventilated, and clean workspace. Protect equipment from moisture, dust, and corrosive gases. Keep surrounding areas clear to ensure adequate space for maintenance. ConclusionThe key to extending the service life of softgel encapsulation machines lies in a "prevention-first, regular maintenance, and precise control" approach. By implementing targeted maintenance, strictly following established schedules, and adhering to operational requirements, enterprises can effectively reduce failures, minimize wear, extend equipment life, maintain consistent product quality, improve production efficiency, and lower overall operating costs.