Algae Oil Softgel Manufacturer for Vegan Omega-3 Brands

The plant runs rotary die encapsulation lines for oil-based fills. Algae oil is sensitive to heat and oxygen, so the fill room is temperature-controlled and nitrogen flushing is available on the oil line. Typical output is 300,000 to 600,000 softgels per day depending on size and shell formulation. For a 500 mg oval, a 1,000-unit pilot run and a 500,000-unit retail order use the same equipment and the same process parameters.

Drying and finishing follow encapsulation. Softgels pass through tumble dryers and then a drying tunnel at controlled humidity, typically 24 to 72 hours depending on shell thickness. After drying, they are inspected, polished and held for QC release before bottling. Bottling runs cover 30, 60, 90 and 120 count, with induction seals, child-resistant caps and desiccant options. Bulk softgels in food-grade drums are also available if you fill in-house.

Algae oil is derived from fermented microalgae, most commonly Schizochytrium sp. Standard grades carry 35–40% DHA and 10–15% EPA, or a higher DHA ratio for prenatal and cognitive-positioned products. Oil is sourced from suppliers with documented fermentation and refining processes, and each lot arrives with a certificate of analysis covering fatty acid profile, peroxide value, anisidine value and heavy metals. You can set a minimum DHA or total omega-3 claim on the finished label.

Shell formulation matters as much as the fill. Standard shells use bovine or porcine gelatin. For vegan and vegetarian labels, we use modified starch or carrageenan-based shells, which are slower to dry and need tighter humidity control. Shell plasticisers, opacifiers and colours are adjustable. Common requests include carob, titanium dioxide-free opaque white, and natural colours such as chlorophyllin. Enteric and delayed-release shells are available for products where a fishy reflux or stomach-release profile is a concern.

Every batch is tested before release. Incoming algae oil is checked for identity, fatty acid profile, oxidation markers and contaminants. Finished softgels are tested for fill weight, disintegration, microbial limits and, where relevant, residual solvents. Retain samples are kept for the shelf-life period. Stability studies at accelerated and ambient conditions support a 24-month shelf life, and we can run a real-time study for your specific shell and packaging combination.

Documentation covers certificates of analysis, GMP, ISO 22000 and HACCP records, plus halal or vegan certification where the formulation requires it. The facility is FDA-registered for dietary supplements. Shipping is by air or sea from Shenzhen or Hong Kong. Air freight typically takes 5–10 days to the US or EU; sea freight takes 25–40 days. We handle export documents, commercial invoices and packing lists, and can work with your freight forwarder or arrange door-to-door delivery.

Every algae oil softgel batch is tested against a written specification before release. Identity is confirmed by fatty acid profile (GC-FID), and potency is assayed for DHA and EPA content, with typical fill tolerances of ±5% of label claim. Microbial testing covers total aerobic count, yeast and mould, E. coli and Salmonella. Heavy metals (lead, cadmium, arsenic, mercury) are tested against EU and US pharmacopoeial limits, and disintegration is checked to USP <2040> for softgels. Testing occurs on incoming oil, on the bulk fill before encapsulation, and on the finished softgel.

The certificate of analysis (COA) issued with each batch lists batch number, production date, expiry date, fill weight, DHA and EPA content, peroxide value, anisidine value, microbial results, heavy metals and disintegration time. Retention samples of every batch are held for 24 months at 25°C/60% RH, and accelerated stability at 40°C/75% RH is run for three months to support a two-year shelf life. If you need a specific marker, such as total omega-3 or a particular sterol profile, state it at quotation so the specification and COA template can be agreed before the first batch.

Documentation is provided in English as standard, with Chinese or bilingual versions on request. Batch records are retained for five years and can be made available for audit. For algae oil softgels, we also record the origin and refinement status of the oil, since oxidation control is critical to taste and shelf life. Each batch is nitrogen-flushed during encapsulation and packed under nitrogen where the format allows. This is not a marketing claim but a process control that is recorded in the batch file and reflected in the peroxide value on the COA.

Algae oil softgels can be packed in HDPE bottles (30, 60, 90, 120 or 180 count), blister packs, stick packs or single-serve sachets. Bottles are induction-sealed and fitted with child-resistant or standard caps depending on market. Desiccant is added where humidity exposure during shipping is a risk. For Amazon and retail, we can apply FNSKU labels, poly-bag the bottles and print carton markings to your specification. Carton dimensions and pallet configurations are agreed at order stage: a typical 60-count bottle carton holds 24 units, with 48 cartons per pallet layer and up to 20 layers per pallet, depending on bottle size.

Labels must include the FDA dietary supplement statement of identity, net quantity, ingredient list, supplement facts panel, directions, warnings and the manufacturer or distributor name and address. We can print labels from your artwork or supply blank bottles for your own labelling. Lot and expiry coding is applied by inkjet or laser on the bottle and carton. Expiry is set from the stability protocol, normally 24 months from production when the oil is nitrogen-protected and the bottle is induction-sealed.

For EU retail, the label must also carry the food supplement symbol, the recommended daily portion, a warning not to exceed it, and storage instructions. Allergen declarations are not normally required for algae oil, but the shell may contain glycerol, carrageenan or modified starch, which must be declared. We check artwork against the destination market's basic requirements before printing, but final legal review remains with the brand owner. Retail-ready packaging, including shelf-ready trays and display cartons, can be quoted separately.

The standard MOQ for algae oil softgels is 1,000 units per SKU for retail bottling. Pilot runs below this are possible, with a minimum of 500 units, but the unit cost is higher because setup and cleaning are spread over fewer softgels. Samples are produced in 7–10 working days after artwork and specification approval, and sample costs are credited against the first mass-production order. Mass production runs 20–35 working days after sample approval, depending on softgel size, fill weight and packaging format. Larger orders and multi-SKU orders are scheduled to share encapsulation runs where the fill is identical.

Shipping is by air or sea. Air freight from Guangdong to Europe or North America typically takes 5–8 days door to door, while sea freight takes 25–35 days port to port. We quote EXW, FOB Shenzhen or Hong Kong, and DDP for selected destinations. DDP includes customs clearance and duties but requires a valid importer of record and product compliance in the destination market. For small orders, air freight is often more economical once inventory carrying cost is considered; for repeat orders above 500 kg, sea freight is usually lower per unit.

Documents provided with each shipment include the commercial invoice, packing list, COA for each batch, MSDS, and a free-sale certificate where required. A phytosanitary certificate is not normally relevant for softgels, but a health certificate can be arranged if your market requires one. We do not provide certificates of origin unless requested at quotation, as the form and issuing body vary by destination. All documents are issued in English, and we can coordinate with your freight forwarder or use our nominated forwarder for FOB and DDP terms.