Encapsulation Technologies

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.

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.

Innovagel® closed process vessels are used to transfer and manufacture fill material under vacuum conditions. 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 the world’s leading technology, 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.