Melting
Gelatine released by the Quality Control Department is added in a large tank. Filtered water from the reverse osmosis (RO) plant is added in the tank and the gelatine is heated to 70 °C. Once the gelatine is dissolved completely, a vacuum pump sucks out the air bubbles in the gelatine.
Colour Addition
After the gelatine solution is transferred to smaller transfer tanks, titanium dioxide is added if opaque capsules are required. FDA approved colour pigments are added by our colour specialists in the appropriate combination to make the desired colour shade. Once the gelatine solution arrives at the exact required colour shade, the tank is moved to the capsule production machine.
Capsule Production
Sorting And Inspection
Camera inspection machines are used in this stage which take continuous photos in a moving conveyor belt from all angles. Any remaining defects are detected by the software in the photo and imperfect capsules are thrown in the rejected bin.
Printing
Information such as company name, product name or logo can be printed on the capsule axially (straight) or radially (circularly around the capsule) in a variety of ink colours. Double printing can be done simultaneously, the cap in one colour and the body in another colour.
Packaging
All capsules are packed in standardised large corrugated cardboard boxes lined with polythene bags. Each bag is closed with a safety seal. For insulation, polystyrene sheets are placed inside the box on all six sides. The box is labelled with the recommended storage conditions of 25°C and 35%-65% R.H. The quantity of capsules per box are kept according to capsule size:
- Size: 0, Number of capsules in carton: 100,000
- Size: 2, Number of capsules in carton: 175,000
- Size: 3, Number of capsules in carton: 225,000