Vegan Softgel Manufacturer for Plant-Based Supplement Brands

EUPHM operates three rotary die softgel lines dedicated to plant-based shells. Each line runs at 60,000 to 90,000 softgels per hour, depending on fill viscosity and shell thickness. We handle batch sizes from 500 units for pilot runs up to 2 million units per SKU for established brands. The facility maintains separate material handling for vegan and gelatin-based production to prevent cross-contact. Cleaning validation between runs follows a documented SOP with swab testing for gelatin residue.

Drying is the critical step for vegan shells. Tapioca and carrageenan require longer and more controlled drying than gelatin. Our drying tunnels hold 22-25 degrees Celsius and 25-35 percent relative humidity for 48 to 72 hours. This reduces the risk of shell brittleness and fill leakage. Incoming tapioca starch and carrageenan are tested for viscosity, moisture and microbial load before release to production.

Not every active works well in a vegan shell. We recommend tapioca-carrageenan for oils and oil suspensions, and modified corn starch for emulsified fills. Common projects include algal omega-3 DHA and EPA, vitamin D3 from lichen, vitamin K2 as MK-7, CoQ10, lutein esters and curcuminoids. Fill weights from 150 mg to 1,200 mg are achievable. Higher fill weights may require a larger oblong shell and a plasticiser adjustment to maintain shell elasticity.

Taste and odour masking is available for ingredients such as algal oil and curcumin. We can add natural flavour systems or use a nitrogen flush during encapsulation to reduce oxidation. Enteric vegan softgels are also possible using a cellulose-based coating. This is useful for probiotics and sensitive peptides that need to bypass stomach acid. We provide a formulation feasibility report within 5 working days of receiving your active ingredient specifications.

Every vegan softgel batch is tested for appearance, fill weight, shell thickness, disintegration and microbial limits. Disintegration testing follows USP <2040> for dietary supplements. We also run accelerated stability studies at 40 degrees Celsius and 75 percent relative humidity for 3 months, and real-time studies for 24 months. Certificates of analysis are issued per batch. The facility is FDA-registered and holds GMP, ISO 22000 and HACCP certification.

For halal claims, we source carrageenan and tapioca starch from approved suppliers with valid certificates. Vegan status is verified through supplier declarations and internal audits. We do not run gelatin on the same lines without a full cleaning and swab validation. Documentation for EU, UK and Middle East import includes certificate of origin, health certificate and allergen statements. Lead time for full export documentation is 3-5 working days after batch release.

Every vegan softgel batch is tested at three stages: incoming raw materials, in-process fill and shell checks, and finished product release. Incoming tests cover identity and potency by HPLC or GC, microbial limits by USP <61>/<62>, heavy metals by ICP-MS, and for the shell, gelling agent viscosity and moisture. In-process checks include fill weight variation (target ±5%), seam integrity by visual and pressure testing, and shell thickness. Finished softgels are tested for disintegration per USP <2040> (typically under 30 minutes for non-enteric), potency, microbials, and where relevant, residual solvents.

A Certificate of Analysis (COA) is issued for each batch and includes: product name, batch number, manufacturing date, expiry date, tests performed, specification limits, results, and a pass/fail statement. It also lists the reference methods used. Retention samples from each batch are kept for the full shelf life plus six months, stored under labelled conditions. Stability protocols follow ICH Q1A(R2) guidelines: 25°C/60% RH for long-term and 40°C/75% RH for accelerated, with testing at 0, 3, 6, 9, 12, 18 and 24 months for long-term and 0, 1, 2, 3 and 6 months for accelerated.

For vegan claims, we maintain segregation of plant-derived shell materials from gelatin lines. Cleaning validation records and allergen cross-contact assessments are available on request. Each batch's documentation pack includes the COA, batch record summary, and deviation reports if any. This supports your own quality agreement and audit trail. We do not release a batch until all tests meet specification and the QA team has signed off.

We offer primary packaging in HDPE bottles (30, 60, 90, 120, 180 and 240 count), blister packs (PVC/PVDC or alu-alu for moisture-sensitive fills), stick packs and sachets. Bottles can be supplied with induction seals, desiccant canisters and child-resistant closures. Labelling follows FDA dietary supplement requirements: statement of identity, net quantity, supplement facts panel with serving size and % Daily Value where applicable, ingredient list, allergen statement, and manufacturer/distributor contact. We print lot numbers and expiry dates by inkjet or laser, with format matching your specification.

Carton and pallet specifications are agreed per order. Standard export cartons are 5-ply corrugated with a 20 kg maximum gross weight. Pallets are 1200 x 1000 mm or 1200 x 800 mm, stretch-wrapped and strapped, with a maximum height of 1.8 m including pallet. We can print your Amazon FNSKU barcodes and apply them to each unit, and we can provide retail-ready cartons with scannable GS1-128 labels. For Amazon FBA, we follow your packing instructions including poly-bagging and suffocation warning labels where required.

Before production, we provide a labelling proof for your approval. This includes dieline, font sizes, and placement of mandatory statements. We recommend a third-party label review if you are launching in the US or EU. Our team can also advise on vegan logo usage and the substantiation you need to keep on file. Packaging materials are food-grade and meet EU 10/2011 and FDA 21 CFR 174-186 requirements where applicable.

Sample production for vegan softgels takes 7-10 working days after formulation and shell specification are agreed. Samples are supplied free of charge for standard formulations; you cover courier costs. Mass production runs 20-35 working days after sample approval and receipt of deposit. MOQ is 1,000 units per SKU for retail bottling, with pilot runs from 500 units. For custom shapes, MOQ is 10,000 units. Lead times are confirmed at order acknowledgement and are subject to raw material availability.

We ship by air or sea. Air freight typically takes 5-10 days door to door, while sea freight takes 25-40 days depending on destination port. We offer EXW, FOB Shenzhen or Hong Kong, and DDP for selected markets. DDP includes customs clearance and duties, but you remain responsible for product compliance in your market. For each shipment we provide a commercial invoice, packing list, bill of lading or airway bill, COA, MSDS, and a free-sale certificate. Phytosanitary certificates are provided only when plant-derived materials require them for your destination.

We recommend booking freight at least two weeks before production completion to avoid storage charges. Our logistics team can coordinate with your forwarder or arrange door-to-door delivery. For repeat orders, we keep a production slot reserved if you provide a 12-week forecast. Payment terms are typically 30% deposit with balance against copy of shipping documents, though terms can be discussed for established customers.