When it comes to softgel production, keeping moisture under control is more than just a technical hurdle. It can affect the entire outcome from the shape and feel of the capsule to the stability and shelf life of the product. Excess moisture at any point in the process can cause clumping, stickiness, or even product breakdown over time. That’s the kind of thing that can put a whole batch at risk.
So whether you’re new to softgels or managing an existing line, understanding how and why moisture problems happen is key. From processing environments to storage spaces, many things can affect moisture levels. But the good news is, there are ways to keep it in check. With the right setup, equipment, and habits, you can keep your production line running smooth and your softgels looking and performing as they should.
Common Causes Of Moisture Problems In Softgel Manufacturing
Moisture-related issues can sneak in at different stages of softgel production. If you’ve ever noticed softgels sticking together or changing shape, moisture likely played a role. Here’s a closer look at what could be going on.
First, there’s humidity in the environment. Softgel capsules are sensitive to air moisture, especially during fill and sealing stages. High relative humidity can cause the shell to absorb water, which leads to problems like softening, warping, or films not sealing properly. Things may seem fine at first, but finished capsules may not hold up once bottled and stored.
Another common trigger is inconsistency in room temperatures. When the production space isn’t kept stable, it’s easier for condensation to build up. That thin layer of moisture could ruin the shell’s integrity or even affect the ingredients inside.
Storage practices also matter. Raw materials, especially gelatin, can soak up extra moisture from the air if not stored correctly. And if your finished product is stored in rooms without proper climate control, softgels may pull in more moisture than they should. Even a short time in a humid corner of a warehouse can do damage.
The good news is that by spotting these common moisture culprits early on, it’s much easier to put the right controls in place.
Best Practices For Moisture Control In Production
Once you know what causes moisture troubles, taking the right steps becomes much easier. Setting up your space and routines to limit moisture can make a noticeable difference for your softgel production. Here are some ways to start:
- Use dehumidifiers: Keeping the environment dry is important, especially during fill and closure. Dehumidifiers help maintain consistent conditions by pulling excess water from the air.
- Invest in quality HVAC systems: Centralized systems with climate control give you better command over how dry or cool your rooms stay, no matter the season.
- Seal raw materials properly: Any materials that can absorb water like gelatin or empty capsules should be stored in airtight containers. Keep them away from heat sources and use humidity-controlled storage rooms when possible.
- Rotate stock regularly: Monitor expiration dates and avoid letting raw supplies sit too long. That minimizes their chance of absorbing extra moisture.
- Stick to preventive maintenance: Regular cleaning and upkeep of your production equipment helps prevent condensation and keeps fans and filters operating properly.
It’s a good idea to build moisture checks into your day-to-day process. Having set times to check humidity levels or storage conditions can help catch issues early. Some facilities schedule specific checks throughout the day to review room conditions or rotate materials. If you’re running a larger operation, keeping logs helps spot patterns and make adjustments.
Staying ahead of moisture issues doesn’t have to involve fancy technology. It’s about sticking to practical methods and getting everyone on the team involved so nothing falls through the cracks.
Packaging Solutions To Prevent Moisture Issues
Once production is handled, the next area that deserves just as much attention is packaging. Even if your softgels come off the line in perfect shape, poor packaging can lead to moisture problems during storage or transport. A strong packaging process can help ensure your product stays protected the moment it leaves your facility.
One of the easiest ways to reduce moisture exposure is by using water-resistant materials. This can include foil laminates, polyethylene bottles, or barrier films. These materials are designed to block outside humidity from reaching softgel shells. In particularly humid regions or during summer months, using thicker bottles or sealed blister packs is a smart precaution.
You can also consider vacuum sealing or flushing the container with an inert gas like nitrogen. This reduces oxygen inside the packaging and helps prevent moisture from building up. It’s a small adjustment that can have a big payoff when distributing products across different climates.
To go a step further, you might include moisture-absorbing packets, like silica gel, inside the packaging. These packs collect leftover humidity that gets past the initial barrier. These are most useful if your product will be stored for a while, or if climate conditions are less predictable during transport and warehousing.
Though packaging might seem like the final step, it’s actually a key protective measure. Done right, it significantly improves how well your softgels hold up after leaving the line.
Why Working With An Experienced Manufacturer Matters
There’s a lot that goes into softgel manufacturing. From ingredient prep to forming, drying, and packaging, each step needs careful planning. And if moisture gets into the mix, every part of the process can be affected.
That’s where your manufacturing partner comes into play. A strong softgel manufacturer isn’t just about having the right equipment. They follow strict humidity standards, control production conditions, and use smarter storage for sensitive materials. They build these controls into their process so you don’t have to track every detail on your own.
It helps even more if the manufacturer operates in a GMP-certified facility. That usually means climate systems, maintenance schedules, and routine checks are already in place. The team doesn’t wait to be told when to test humidity or review storage conditions. It’s part of the routine.
Experienced manufacturers also understand the impact of specific ingredients on moisture stability. Let’s say you’re creating a fish oil softgel. It may require extra attention during the warmer months. A seasoned manufacturer would know to adjust their storage and production conditions to match the product’s needs. That foresight prevents breakdowns before they start.
Reliable softgel partners make all the difference. Their experience helps protect your batch from issues you might not even see coming.
Keeping Your Softgels Stable With Seasonal Prep
A big part of preventing moisture issues is staying prepared throughout the year. Seasonal changes, especially in late summer, can sneak up on your operation. When humidity peaks and temperature swings become more frequent, you’ll want to step up your checks to match.
Start by increasing your monitoring schedule during these months. That could mean more frequent checks of indoor humidity, storage room temperatures, or even reviewing local weather forecasts that may impact transport. Even a day stuck in the back of a hot truck can ruin a batch if packaging and handling aren’t dialed in.
It’s also helpful to assess your warehouse setup as the seasons change. Check that all HVAC units are working properly. Swap out old filters. Make sure seals on doors and containers are holding. And rotate out any older finished goods so fresh product isn’t sitting behind stock that’s already absorbed moisture.
Here’s an example. A brand launched a softgel line in August and shipped from a high-humidity region. The products weren’t packed with moisture control packets. By the time they hit store shelves, the softgels had clumped together. Just by upgrading the bottles and adding a simple silica pouch, the product could’ve stayed in great condition through transport and storage.
Being proactive about seasonal prep of softgel production doesn’t take too much effort, and it helps keep customer complaints—and lost batches—to a minimum.
What It Takes To Keep Softgels Moisture-Free
Moisture issues with softgel production don’t usually come out of nowhere. They happen from small oversights along the way, like poor temperature control or packaging that wasn’t built for the conditions. Once you understand how those breakdowns happen, it becomes easier to put smart fixes in place.
Rethinking some of your workflows, improving your packaging, or choosing the right equipment won’t just prevent product loss. It helps your softgels look better, last longer on the shelf, and make a stronger impression on your customers. Take the time to plan for heat, humidity, and storage challenges, and your brand will be in a much better place.
To maintain the integrity of your products and ensure their quality, partnering with a seasoned softgel manufacturer is key. At Alaska Spring Pharmaceuticals, we’re here to help you tackle any moisture challenges and keep your production line efficient. Learn more about how we can support your supplement formulations today.
