Mini Softgel Manufacturer for Compact-Dose Brands

Mini softgels typically run between 50 mg and 300 mg fill weight, with shell thickness from 0.25 mm to 0.40 mm. Our rotary die lines hold fill-weight variance within ±3% for oil-based actives and ±5% for suspensions. That matters for products where a 10 mg difference in a 100 mg dose changes the label claim. We run 6 mm to 11 mm oblong and round dies, and can produce enteric or vegetarian shells on the same platform.

Capacity reaches 180,000 mini softgels per shift across two lines. That covers pilot batches of 1,000 units and recurring retail runs of 500,000 units per SKU. For brands moving from a standard 500 mg softgel to a 150 mg mini format, we adjust fill weight and shell formulation together to keep the active dose identical. Drying and polishing take 18–24 hours before packing.

Mini softgels handle oils, suspensions and paste-like actives. Common fills include vitamins A, D, E and K, CoQ10, omega-3 concentrates, lutein, zeaxanthin and astaxanthin. For 50 mg to 150 mg doses, we often use medium-chain triglycerides as the carrier and add lecithin to keep suspensions stable. Antioxidants such as mixed tocopherols protect oxidation-sensitive fills. We test viscosity before filling to avoid shell deformation on small dies.

The shell can be bovine, porcine, fish or vegan (modified starch or carrageenan). For halal certification, we source gelatin from approved suppliers and retain chain-of-custody documents. Organic claims require certified actives and a separate production clean-down. We can produce two-piece or seamless mini softgels depending on the fill. Flavour masking is limited in small formats, so we recommend coated or enteric shells for bitter actives.

Every mini softgel batch is tested for fill weight, shell thickness, disintegration, microbial limits and heavy metals. We retain samples for 24 months. Certificates of analysis include assay results for each active. The facility is GMP-certified, ISO 22000 and HACCP compliant. Halal certificates are available per batch. certification covers specific lines. We do not claim FDA approval; the facility is FDA-registered for dietary supplements.

Export packing runs from 30-count to 180-count HDPE bottles, blister packs and sachets. We ship from Shenzhen and Hong Kong ports. Standard lead time for mass production is 20–35 working days after sample approval. Air freight samples arrive in 3–5 working days. Documentation includes commercial invoice, packing list, certificate of origin, health certificate and certificate of analysis. MOQ for retail bottling is 1,000 units per SKU.

Every mini softgel batch is tested against a written specification before release. Identity and potency are confirmed by HPLC for actives such as vitamins, CoQ10 or herbal extracts, with results compared to the approved formula. Microbial testing covers total aerobic count, yeast and mould, E. coli and Salmonella. Heavy metals (lead, arsenic, cadmium, mercury) are screened by ICP-MS. Disintegration testing follows the USP <2040> method for softgels, with a typical limit of 30 minutes in purified water at 37°C. These tests run on the bulk blend where relevant and on the finished softgel.

A certificate of analysis (COA) accompanies each batch and lists the product name, lot number, manufacture and expiry dates, fill weight, appearance, identification result, assay value as a percentage of label claim, microbial results, heavy metals results and disintegration time. Where a customer requires it, the COA can also include residual solvent and allergen statements. Retention samples of every batch are held for the shelf life plus six months, stored under labelled conditions. This allows re-testing if a market complaint or regulatory query arises after export.

Stability follows a protocol agreed at the quotation stage. Accelerated conditions at 40°C and 75% relative humidity are run for three and six months, with real-time data at 25°C and 60% relative humidity for the declared shelf life, typically 24 months for mini softgels. Tests at each interval cover assay, disintegration, microbial limits and appearance. For markets requiring a specific shelf life, such as 18 months at 30°C, the protocol is adjusted before production. Stability data is shared with the brand owner and kept on file for audit.

Mini softgels can be packed in HDPE bottles from 30 cc to 250 cc, blisters of 10 to 30 cavities, stick packs or sachets. Bottle fills are checked by weight and count, with induction sealing and a desiccant option for hygroscopic fills. Blister material is typically PVC/PVDC or alu-alu for moisture-sensitive actives. Cartons are printed to the artwork supplied by the brand owner, and each unit carries a lot number and expiry date in the format agreed at order confirmation. Case packs and pallet configurations are specified before production so that the retail unit matches the shelf and shipping plan.

For the US market, the label must include the supplement facts panel, serving size, amount per serving, percent daily value where applicable, ingredient list, allergen statement, and the manufacturer or distributor address. The FDA does not pre-approve labels, so the brand owner is responsible for claims and structure-function statements. EUPHM can review artwork for obvious omissions such as missing lot fields or incorrect net quantity, but final label compliance remains with the brand. For Amazon, the FNSKU label can be applied in-house, and units can be poly-bagged or shrink-wrapped to meet retail requirements.

Carton and pallet specifications are confirmed with each order. A typical shipper is a five-ply corrugated carton with a net weight of 8 to 12 kg, and pallets are 1,200 x 1,000 mm or 1,200 x 800 mm depending on the destination. Pallet height is kept below 1.8 m for container loading, and each pallet carries a label with lot number, quantity and carton count. For retail buyers, EUPHM can provide a packaging specification sheet listing dimensions, materials and barcode placement. These details are checked against the approved artwork before the first carton is printed.

Sample requests for mini softgels are handled within 7 to 10 working days from receipt of the formula and fill weight. If a stock formulation is used, samples can be dispatched sooner. The sample pack includes the softgel in a labelled bottle, a draft COA and a specification sheet. Buyers should confirm the fill weight, capsule size and target shelf life at this stage, because changes after sample approval can add 5 to 10 working days to the production window. Pilot runs from 1,000 units are available for brands that need to test the market before committing to 1,000 units.

Mass production runs 20 to 35 working days after sample approval, depending on the number of SKUs and whether packaging is stock or custom printed. Custom cartons and labels add 7 to 12 working days for print and approval. For a 5,000-unit mini softgel order, the typical production window is 25 working days, with dispatch from Guangdong within 3 working days of final release. Line capacity of up to 180,000 mini softgels per shift means larger repeat orders can be scheduled without changing the formulation or the approved packaging.

Delivery terms are quoted as EXW, FOB or DDP. FOB Shenzhen or Hong Kong is common for buyers with their own freight forwarder, while DDP is used for Amazon FBA and small retail orders where the brand owner prefers a delivered price. Air freight takes 5 to 8 days door to door for urgent launches, and sea freight takes 25 to 40 days depending on the port. Documents provided with each shipment include the commercial invoice, packing list, COA, MSDS, free-sale certificate and, where relevant, phytosanitary certificate for botanical ingredients. Certificates of origin can be arranged on request.