How Are Gel Caps Made?

Definition

A gel cap is a medical tablet that is coated in gelatin for easier swallowing or use as a suppository. The tablet contains medicine in either a powder, liquid or paste form that is processed by the body after the gel capsule dissolves in the digestive system. Gelatin is ideal for this purpose because of its unique ability to thicken and gel as well as the fact that it is hypoallergenic and fat-free. While most gel caps are made of traditional gelatin composed of animal skins and bones, there are vegetarian options made of plant fibers that don't dissolve as quickly.

The Preparation

The raw materials that make gelatin, normally pig and animal skin and bones, are processed and treated with alkaline solutions to remove any remaining hair and make sure they are clean. They are then separated into three layers, with the middle layer being what is needed for gelatin production. Lime or salt is added to this middle layer as a preservative, and then the layer is sent to a factory where it is washed again and cut down to hand-sized pieces. Bones are cut down to small pieces and demineralized to form a material called ossein.

Final Production

The raw material is either subjected to a three-day acidic process where it is treated with acid or alkaline for several weeks. It depends on what type of gel is being made. The material is then mixed with warm water before being subjected to the extraction process. The initial gel is obtained at low temperature and then warmer water is added to extract the remaining amount at a higher temperature. This continues until the final remains of gel are extracted with the use of boiling water. Very little remains after extraction is finished.

Creating Gel Caps

A thin film of gelatin (or the plant fiber material for vegetarian varieties) is applied to stainless steel pins. As it dries on the pin, it hardens to form a capsule. The capsule is removed from the pin and sent to a filling machine that uses a needle to fill the capsule with medicine, normally in a liquid, powder or paste form. The filled gel caps then get sent for packaging.