Softgel Solutions

CREATE SUCCESS WITH CUSTOM-CRAFTED SOFTGELS

KD Nutra®´s softgel center of excellence is your go-to partner for nutritional supplements and FDA-certified OTC pharmaceutical manufacturing. Our seasoned team of professionals has decades of experience in developing and manufacturing softgel capsules. We look forward to combining our technical capabilities with your vision to bring winning products to life – quickly and cost effectively.

ADVANCED INNOVAGEL® TECHNOLOGY

KD Nutra® focuses on innovation when it comes to softgel production and technology. KD Nutra® manufactures a variety of softgel products thanks to its Innovagel® technology tool box. This advanced technology deliver high-end products including viscous suspensions, oil mixtures, 50% solid fill formulations, as well as suspension or hydrophilic excipient-based products. From simple oils to complex suspensions, our advanced Innovagel® technology processes are optimized to deliver consistent quality softgels. We focus on uniformity and stability of complex suspensions, shell and seam strength to avoid leakers, and prevention of oxidation throughout the manufacturing process. The scientific and technical teams are ready to help create innovative products that serve consumers’ needs, while setting your brand apart from the competition. Our current focus is on the following product categories:

• Fish and Algae omega-3 essential fatty acids in all forms, concentrations, and ratios
• Innovative Omega-3 blends with other proprietary ingredients
• Single and multi-nutrient blends
• Herbal blends
• Non-animal gelatine softgels for a complete vegan solution

STATE-OF-THE-ART MANUFACTURING FACILITY

With FDA, TGA and NSF approval, as well as over 30 years of experience developing and manufacturing premium softgels, KD Nutra®’s world class facility provides a complete turnkey solution for dietary softgel products. KD Nutra® has the ability to accommodate both small and large volume projects, offering 7 encapsulation production lines, with capacity to produce 2 billion softgels per year.

Our Innovagel® technology processes uses high quality softgel machines from Canada and Japan, with customization performed in Switzerland. We utilize crib room tooling organizational controls and maintain all critical machine components on site. We have implemented proprietary in-process controls throughout manufacturing, including high-resolution microscopes for particle sizing and softgel seam measurement, as part of our effort to achieve uniformity of fill and seam strength of the shell. Our tumbler drying process eliminates drying variability and enables efficient and cost-effective segregation of defects, as well as assisting with highly accurate and quick Root Cause Analysis.

Innovagel® closed process vessels are used to transfer and manufacture fill material under vacuum conditions ensuring a low exposure contamination. This happens in conjunction with inert gas blanketing to protect oxygen sensitive ingredients such as Omega-3 fish oils. For suspension fill products, powerful milling equipment is used to obtain an internal particle size specification. This process ensures that the fill material maintains uniformity throughout the encapsulation process and prevents defects caused by large particles. KD Nutra® has two large gelatin melting vessels and selects the best formulation based on product fill material and softgel size.

Innovagel® encapsulation processing equipment utilizes Critical Quality Attributes (CQA) which is integrated within the production process to achieve the highest level of quality. A specialized microscope is used to measure the capsule seam and shell thickness. This information is then attached to the master batch record.

Innovagel®’s critical components such as die rolls, segments and spreader boxes are maintained on site for precision manufacturing. This also includes a continuous drying process that uses individual tumbler baskets. This unique process provides a more consistent overall product and is more efficient than tray drying.

Thanks to our continuous innovations in softgel manufacturing, we have developed the ability to manufacture delayed release and gastric resistant softgel products without the use of a secondary coating process. The absence of a secondary coating eliminates the hazy appearance of traditional enteric coated softgel products. Our delayed release technology protects acid-labile active ingredients and reduces gastric irritation and reflux by allowing the shell to breakdown in the small intestine instead of the stomach. This leads to improved bioavailability, while also eliminating the occurrence of any unpleasant taste.

KD Nutra® has developed a breakthrough nutritional platform of vegan omega-3 concentrates from algae and now, thanks to its Innovagel® technology processes, can manufacture plant-based softgels suitable for vegan and vegetarian consumers. These will be manufactured using a proprietary technology that allows for an extended release and improved bioavailability. Additionally, it will have better performance in extreme pH and higher temperature conditions, compared to standard animal gelatin.

We have extensive experience in serving the Canadian, South American, European, Middle East, Asian, and Australian markets – either directly or through global brands. KD Nutra® is IFANCA-authorized to manufacture Halal Certified Products.

At KD Nutra® we use multiple state-of-the-art purification technologies processes which allow for the production of the highest fish and algal omega-3 concentrations on the market. Higher oil concentrates can be encapsulated in smaller dosage per serving, which result in improved consumer compliance and additional room for complementary ingredients. 

From size 2 oval to size 28 oblong, we can deliver a full range of sizes and shapes to serve your needs. We have twist-offs and cut-offs and will work with you in making custom dies if desired. Additionally, Innovagel® high speed imprinting as well as laser etching machines can help to brand your softgels.

Contact us to discover how our Innovagel® technology can bring your product concept to life!

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