Softgels are the format of choice whenever the active ingredient is an oil, a fat-soluble vitamin or anything that degrades when it is heated or compressed. They are also one of the least forgiving formats to manufacture, because an oil fill and a gel shell must stay in balance for the whole shelf life. This guide covers what buyers should decide before briefing a manufacturer.
Why softgels rather than tablets or capsules
Tableting compresses and heats the blend; two-piece capsules hold dry powder. Neither suits an oil. A softgel is formed by filling a plasticised gel ribbon, sealing it, then drying the finished capsule — no compression and no heat, which is why fish oil, CoQ10, black seed oil, garlic oil, astaxanthin, lutein and fat-soluble vitamins such as A, D, E and K are almost always delivered this way. Softgels also protect the fill from oxygen far better than a capsule or an open bottle, and they hide taste completely, which matters for oils like cayenne or garlic.
Anatomy of a softgel: shell and fill
- Shell — gelatin is the traditional base, giving the clearest, strongest shell. Vegetarian shells use modified starch, carrageenan or HPMC, and are the right choice for plant-based positioning.
- Plasticiser — glycerol or sorbitol keeps the shell flexible. The ratio of plasticiser to gelatin controls hardness; too much and the capsules stick together in the bottle.
- Fill — a straight oil, an oil suspension with micronised actives, or a paste. Fill weight decides the final capsule size, and actives such as lutein or CoQ10 are usually suspended rather than dissolved.
Because the fill is liquid, the fundamental question for a new formula is how many milligrams of active can be suspended in a single fill without settling. That answer sets your dose count.
Formulation variables that decide quality
- Oxidation. Omega oils, CLA and black seed oil all oxidise. Insist on a peroxide value and an anisidine value on the incoming oil, and on nitrogen flushing or an antioxidant system in the fill.
- Shell thickness and shape. Oblong, oval and round moulds are standard; a thicker shell slows oxidation but looks larger for the same fill weight.
- Delivery profile. A standard softgel releases in the stomach. Enteric or delayed-release softgels are used when the active should pass the stomach — a heavier shell, a special shell polymer or a coating achieves this.
- Chewable softgels. Softer shells for omega-3 and multivitamin chews, usually flavoured and sweetened in the fill.
Stability and packaging
Moisture, light and oxygen drive degradation. Practical controls are opaque or amber bottles, an induction seal or a tight cap, and a nitrogen blanket at filling. Shelf life should be supported by real-time and accelerated stability data rather than assumption — 24 months is a common target for oil-based softgels stored correctly. Ask for a Certificate of Analysis with every batch, covering fill weight, shell integrity and, for oils, oxidative status.
Liquids and oils as a finished product
The same oils frequently ship as a liquid rather than a softgel. Body and massage oils are typically filled into 10 ml, 30 ml or 60 ml bottles or roller bottles, with the base oil chosen for skin feel and the botanical fraction chosen for scent. If you sell both the softgel and the oil, use the same botanical specification so the two carry a consistent story.
Labelling by destination market
Softgels sit in the supplement rules of most markets, not the food rules, so the panel format follows Supplement Facts (United States) or the Nutrition Reference Value and permitted nutrient forms (European Union). Oils sold as cosmetics rather than supplements follow cosmetic labelling and ingredient-naming rules instead — a distinction worth settling before artwork. Gulf and ASEAN markets add their own registration steps.
MOQ, sampling and lead times
Because moulds and shell ribbons are standard, a softgel range is practical to trial. A sensible starting point is MOQ 500 units per SKU, samples in 3–5 days, production shipped within 7 days, and a COA with every batch. That lets a new brand validate one softgel and one oil before committing to a full range.
How Haiyue Shengda works
We produce softgels, capsules, tablets, gummies, herbal tea, powders, drops and creams in our own 5,000+ m² factory with 7 production lines and 34 machines, under FDA facility registration and HACCP, cGMP and ISO 22000. Custom formulations and outer-packaging design are free, with the first design sketch in about two hours. Browse our capsules and softgels, read the FAQ, or contact us — we reply within one hour on working days.