Why Do Softgel Capsules Leak? Key Causes in Manufacturing and Handling
Softgel capsules are a common dosage form in dietary supplement manufacturing due to their ability to contain liquid or semi-solid fills. However, leakage can occur if formulation, process, or handling factors are not properly controlled. Understanding the causes of softgel capsule leakage helps brands and manufacturers reduce quality risks and improve product consistency.
At CSK Biotech, we provide OEM and ODM manufacturing for softgel capsules alongside other supplement formats, supporting global brands with structured production and quality management systems.
What Is Softgel Capsule Leakage?
Softgel capsule leakage refers to the escape of fill material through the capsule shell or seam. This may occur during production, storage, transportation, or extended holding periods and is typically associated with capsule integrity rather than product use.
Common Reasons Softgel Capsules Leak
1. Fill and Shell Incompatibility
Certain oils, solvents, or active materials may interact with the capsule shell, which can:
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Weaken shell structure
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Increase shell permeability
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Affect long-term capsule stability
Compatibility assessment is an essential step in softgel formulation development.
2. Improper Fill Viscosity
If the fill material is:
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Too low in viscosity, it may migrate through the shell
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Too high in viscosity, it may place uneven pressure on the capsule seam
Maintaining consistent viscosity helps support capsule integrity.
3. Capsule Shell Composition
Softgel shells typically contain gelatin, plasticizers, and water. Leakage risks may increase if:
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Shell thickness is inconsistent
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Plasticizer ratios are not optimized
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Moisture content is outside controlled ranges
Shell formulation consistency is critical to capsule performance.
4. Encapsulation and Sealing Parameters
During production, factors such as:
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Sealing temperature
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Pressure at the capsule seam
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Alignment of encapsulation tooling
directly affect seam strength. Inadequate sealing can result in weak points prone to leakage.
5. Drying and Conditioning Process
After encapsulation, softgels must undergo controlled drying and conditioning. Issues may arise if:
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Drying time is insufficient
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Temperature or humidity is not properly controlled
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Capsules are unevenly exposed during curing
Proper conditioning allows the shell to stabilize before packaging.
6. Storage and Transportation Conditions
Post-production handling can also influence leakage, including:
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High temperature exposure
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Excess humidity
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Physical stress during transport
Environmental controls help maintain capsule integrity over time.
How Manufacturers Minimize Leakage Risks
Experienced softgel manufacturers apply multiple control measures, including:
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Pre-production compatibility evaluations
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Controlled encapsulation and drying parameters
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In-process seam inspection
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Environmental monitoring during storage
These measures help maintain consistent quality across batches.
The Role of Manufacturing Expertise
Softgel production requires specialized equipment and process control. Manufacturers with established experience can:
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Identify potential risks early in development
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Optimize shell and fill parameters
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Support stable, scalable production
This expertise is essential for long-term product consistency.
Partner with CSK Biotech for Softgel Capsule Manufacturing
CSK Biotech provides OEM and ODM manufacturing for softgel dietary supplements, offering:
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Controlled softgel encapsulation processes
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GMP-aligned quality management systems
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Support for custom formulations and private label production
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Manufacturing suitable for international markets
To discuss softgel capsule manufacturing or quality considerations, please contact:
We welcome inquiries from global brands seeking reliable and compliant softgel supplement manufacturing solutions.
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FAQ
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What types of dosage forms does CSK Biotech manufacture?
We offer a full range of supplement dosage forms, including:
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· Softgel capsules
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· Hard capsules
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· Tablets
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· Powder supplements
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· Gummy supplements
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· Liquid supplements (drops, syrups, oral liquids)
This allows our clients to build a complete and diversified product line with one reliable manufacturing partner.
Does CSK Biotech provide OEM and ODM services?
Yes. CSK Biotech provides both OEM (Original Equipment Manufacturing) and ODM (Original Design Manufacturing) services.
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OEM: Manufacturing based on your existing formula and specifications
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ODM: Full product development including formulation, dosage form design, and production
Our R&D team works closely with clients to turn concepts into market-ready products.
Can you help with gummy supplement customization?
Yes. Custom gummy supplements are one of our core strengths. We offer:
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· Gelatin or pectin-based gummies
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· Sugar-free or low-sugar options
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· Customized flavors, colors, shapes, and textures
Our gummies are developed with a focus on taste, stability, and consumer appeal.
How long does production usually take?
Production timelines vary depending on:
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· Dosage form
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· Formula complexity
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· Order quantity
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· Packaging requirements
Generally, production takes several weeks after formula confirmation and raw material preparation.
Can CSK Biotech customize formulations?
Absolutely. We offer full formulation customization, including:
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· Active ingredients selection
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· Dosage optimization
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· Flavor and taste adjustment
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· Stability and bioavailability improvement
Our technical team ensures that each formula is safe, effective, and suitable for the target market.
Are your manufacturing facilities GMP certified?
Yes. CSK Biotech operates under GMP (Good Manufacturing Practices) standards. Our production facilities follow strict quality · · · management systems to ensure:
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· Product safety
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· Batch consistency
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· Full traceability of raw materials and finished products
Related Products
Explore our range of complementary dietary supplement products designed to meet diverse formulation and market needs. Each item is developed and manufactured with the same high-quality standards and expertise that define our dietary supplement contract manufacturing services, helping brands expand their product offerings efficiently and reliably.
Request a Quote for Dietary Supplement Contract Manufacturing
If you need CDMO services for health foods, nutritional supplements, or cosmetics, our team of experts is ready to provide you with customized solutions and quotes.
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