Q&A: Formulating Softgels

Becca Putans - Associate Research Chemist, IFF

Manufacturing Technologies

Can you discuss the key manufacturing technologies utilized in the production of plant-based/vegan-friendly softgel formulations, and how do they differ from traditional gelatin-based processes?

For plant-based softgels, it can be a challenge to find the right shell former,, or combination of them, to ensure optimal performance and production efficiency. Commonly used shell-forming technologies are a mix of carrageenan and modified starch, but choosing the right carrageenan is crucial. For instance, iota and kappa carrageenan produce capsule shells that tend to be too soft to withstand mechanical stress during manufacturing and capsule storage. Tailored carrageenan may be the answer, to enable versatility, superior yield, and excellent throughput in soft capsule production – with a quality similar to gelatin.

Alternative carrageenan-free softgel technologies are based on either gellan gum or tailored pectin. Gellan gum can be used to produce high-quality softgels, but they carry a high raw material cost.

The use of tailored pectin for plant-based softgels is a recent development. Launched in 2023, VERDIGEL™ SC from IFF offers a carrageenan-free alternative to other vegan softgel technologies without compromising performance and quality.

What challenges and opportunities arise in adopting these technologies for plant-based alternatives, and how are they addressed in the manufacturing process?

Moving from gelatin to plant-based softgels can pose a variety of formulation challenges, including higher viscosity gel masses, lower encapsulation rates, and weaker seals. The key to success is to use carrageenan in the shell-forming system that has been optimized for use in soft capsule applications. Tailored carrageenan enables production rates of 4+ rpm or more, across a wide range of soft capsule shapes and sizes, tolerating larger formats – accommodating 24 minims and higher. This allows for highly complex and viscous fill materials to be encapsulated with soft capsule quality that rarely leaks, offering upwards of 98% yields.

Manufacturers can also benefit from increased resistance to puncturing or bursting during storage and handling, from higher output and fewer rejected capsules due to the superior shell formation. This can save valuable production costs and time.

Ingredient Selection and Sourcing

How do you approach the selection and sourcing of plant-based ingredients for softgel formulations, considering factors like sustainability, quality, and regulatory compliance?

As the preference for more sustainable and non-animal products grows globally, demand for plant-based ingredients and solutions continues to rise at a rapid rate. We’re now in a new era of supplement innovation where plant-based and performance go hand-in-hand.

Our platform of plant-based softgel solutions comprising SeaGel^® and VERDIGEL™ SC is suitable for a vast range of soft-gel formulations. The carrageenan used in IFF’s SeaGel^® is a naturally occurring hydrocolloid. The seaweed used to produce carrageenan is harvested using sustainable ocean management practices; they don’t use land, so no fertilizers or irrigation is required. Meanwhile, the pectin that gives VERDIGEL™ SC its unique properties is a plant-based hydrocolloid that is produced using a circular economy model. Our pectin is extracted mostly from citrus peel by-products, from the juice and citrus oil processing industries. These by-products would otherwise have been used as animal feed or wasted.

Market Outlook

What trends and developments do you observe in the market for plant-based/vegan-friendly soft-gel formulations, and how have consumer preferences evolved in recent years?

We’ve seen appetite for vegetarian and vegan supplements steadily grow over the past five years and there seems to be no signs of this slowing down. In fact, as many as 45% of consumers say they would like to see more plant-based vitamin, mineral, and dietary supplement products on the market.¹ Although vegan-friendly formulations are becoming more popular across all delivery formats, the shift is most noticeable with hard capsules, softgels, and gummy formats. And while gummies may have seen rapid growth in the past five years, hard capsules and softgels remain the most common delivery systems.

Quality and Stability

Maintaining the stability and quality of softgel formulations is crucial. How do you address challenges related to stability, shelf life, and quality control in plant-based alternatives compared to traditional gelatin-based products?

Pectin is ideal for use in plant-based alternatives, as it is a stable ingredient that is also typically recognized by consumers as a wholesome and safe product of natural origin. Like carrageenan technologies, pectin is easy to implement into the manufacturing process, as it is compatible with industry-standard equipment that is currently used for gelatin softgels.

Pectin soft capsules enable specialized fills, too. They have greater thermal stability than gelatin, which allows filling of more viscous, concentrated materials, since the fill can be heated without melting the capsule shell. This makes them also a great option for e-commerce, as the capsules can withstand shipping and storage heat and humidity.

Applications and Innovations

Can you share any recent innovations or advancements in the development of plant-based soft-gel applications?

In early 2023, IFF achieved an industry-first in encapsulation, with the use of high-viscosity liquid and semi-liquid nutritional ingredients in softgel applications using its SeaGel^® technology. This technical breakthrough allows manufacturers to develop robust, high-quality, plant-based soft-shell capsules that match the performance of traditional animal-based gelatin for complex ingredients. As part of our ongoing work to address softgel technology challenges, this advancement works by encapsulating NovaSOL^® Curcumin and NovaSOL^® Curcumin/ Boswellia from AQUANOVA AG.

We have also been looking at implementing clean-label ingredients that will help address consumer needs while maintaining the manufacturability of dosage forms. VERDIGEL™ SC was launched in 2023: a softgel shell-forming system based on pectin, an ingredient that has an outstanding history of safety and functionality as a food ingredient. IFF has developed several different capsule prototypes using this new shell-forming system. We used standard industry rotary die processes to create 7.5 oval and 20 oblong VERDIGEL™ SC capsules with a range of fill materials. For example, developing capsules using a light omega-3 oil derived from algae as a fill material allowed us to create a fully vegetarian/vegan alternative to traditional fish oil capsules. Plus, other fills such as coconut oil, which requires heating to become flowable, have been filled into VERDIGEL™ SC capsules with comparable quality to other plant-based capsules.

Sustainability Practices

Sustainability is a growing concern. How does your company approach sustainability in the production of plant-based soft-gel formulations, from ingredient sourcing to packaging?

Responsible sourcing is a key focus area for IFF, and we have a supplier engagement program to ensure that our suppliers live up to IFF’s expectations on sustainability. This also involves requirements to comply with SEDEX and or Ecovadis certification. For seaweed, specifically, we also have a dedicated responsible sourcing program, where we work with seaweed farmers and harvesters across the globe to help preserve natural resources while strengthening local communities.

In terms of production, we continuously strive to minimize our impact from greenhouse gas (GHG) emissions, water use, and waste. For GHG emissions, we are committed to reducing our Scope 1 and 2 emissions by 50% and Scope 3 emissions by 30%, from 2021-2030 (these goals are approved by SBTi). We also aim to reach zero waste to landfill by 2030. Water resource management is a priority too; we want to increase water use efficiency across our portfolio, as well as drive collective action for water stewardship in the communities where we source and operate.

Are there specific initiatives or practices in place to minimize the environmental impact of manufacturing and distribution processes for these products?

We’re always looking to reduce the impact of our production and distribution activities. We use life cycle assessments to analyze the environmental impact across the production chains of our products. In 2022, we reduced more than 30,000 metric tons of CO2e from Scope 1 and 2 emissions as a result of our dedicated sustainability and energy capital expenditure fund, keeping us on track to meet our ‘Do More Good’ plan targets. At our pectin plants, for instance, we have implemented measures to reduce energy consumption and waste, such as steam recovery and equipment improvements, as well as a separation system.

https://pharma.iff .com/our-expertise/sustainability

Reference

1. Mintel’s Nutrition Watch: Plant-Based Supplements 2022.

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