Method and apparatus for the manufacture of textured softgels

A softgel having a texture on at least a portion of its surface and a process and apparatus for the manufacture thereof. The process for manufacturing the textured softgel includes forming a flowable gelatin mass, providing a rotary drum having an outer surface, controllably directing a flowable gelatin mass to the outer surface of the drum, forming a gelatin ribbon of substantially uniform thickness on the outer surface of the drum, the gelatin ribbon being initially in a relatively softer and moldable state immediately following the directing step, providing a roller of reduced diameter with a textured surface closely adjacent to the outer surface of the drum, passing the ribbon while in the relatively softer and moldable state between the drum surface and the textured surface while applying sufficient pressure to the roller in the direction towards the drum to cause the textured surface to impart a matching texture on the other surface of the ribbon, providing a second gelatin ribbon, forming a plurality of filled softgels from the gelatin ribbons, the matching texture defining the outer surface of at least of a portion of each of the softgels.

BACKGROUND OF THE INVENTION 
Field of the Invention and Description of the Prior Art 
This invention relates to textured softgels (or soft gelatin capsules) and 
to a process and apparatus for the manufacture thereof. 
Soft gelatin capsules, now more commonly known as softgels, have been well 
known and widely used for many years. Softgels generally comprise an outer 
shell primarily made of gelatin, a plasticizer, and water, and a fill 
contained within the shell. The fill may be selected from any of a wide 
variety of substances that are compatible with the gelatin shell. Softgels 
are widely used in the pharmaceutical industry as an oral dosage form 
containing many different types of pharmaceutical and vitamin products. In 
addition to use as an oral dosage form for drugs and vitamins, soft 
gelatin capsules or softgels are also designed for use as suppositories 
for rectal or vaginal use. Other uses are for topical and ophthalmic 
preparations and the like. The cosmetic industry also uses softgels as a 
specialized package for various types of perfumes, oils, shampoos, skin 
creams and the like. Softgels are available in a great variety of sizes 
and shapes, including round shapes, oval shapes, oblong shapes, tube 
shapes and other special types of shapes such as stars. The finished 
capsules or softgels can be made in a variety of colors. Also, opacifiers 
may be added to the shell. 
Although softgels can be made in a wide variety of shapes, sizes and 
colors, because of the wide range of use of softgels, there is a definite 
need to provide other means of identification. In this regard, it is quite 
common today to have an indicia of some type printed on each softgel after 
formation. The printing material may be any suitable dye or pigment. In 
some equipment, this has the disadvantage of requiring the use of an 
additional machine that will align the softgels and hold them in a desired 
oriented position for the application of the dye or ink. The use of 
additional equipment and procedural steps adds to the overall cost of 
manufacture of the softgels and, therefore, this system is considered 
disadvantageous. Also, the printing of each softgel can be done over only 
a limited portion of the exterior surface of the softgel and may not be 
readily read or even seen by the consumer. Specific examples of known 
processes and machines used for applying some type of identification on 
the softgels are those shown, for example, in Power (Posner) U.S. Pat. No. 
2,449,139; Scherer U.S. Pat. No. 2,623,494; Scherer U.S. Pat. No. 
2,703,047; Scherer U.S. Pat. No. 2,688,775; Taylor U.S. Pat. No. 
3,124,840; Hansen U.S. Pat. No. 3,203,347; and Vincent U.S. Pat. No. 
3,333,031. 
The Posner Patent shows gelatin as one possible type of system that can be 
used in connection with an apparatus for manufacturing and filling 
capsules. In this patent, as seen best in FIG. 9 thereof, a tube of 
gelatin is formed and then a textured brand is applied to a portion of the 
outer surface of the tube. The capsule is then filled and sealed. This 
apparatus is used in quite a different system from the rotary die process 
which is probably the most common type of machine used for manufacturing 
softgels today. The rotary die process is described in some detail in 
Stanley's Chapter 13 of Lachman, Lieberman, and Kanig, The Theory and 
Practice of Industrial Chemistry (Copyright Lea & Febiger, 1970). In the 
rotary die process for manufacturing softgels, two gelatin ribbons are 
prepared, fed simultaneously to the fill area, and simultaneously and 
continuously filled, formed, hermetically sealed, and automatically cut 
between two rotary dies. The disclosure in the article by Stanley, as 
identified above, is incorporated into this specification by reference as 
being quite fully descriptive of the rotary die process, with which the 
present invention is involved, as opposed to the process disclosed in the 
Power patent. 
The Scherer U.S. Pat. No. 2,623,494 relates to a banding machine for 
softgels. In this machine, the identifying band is applied to each 
individual capsule after the capsule is formed. 
The Scherer U.S. Pat. No. 2,688,775 shows a method for applying a brand to 
the exterior surface of a gelatin capsule. 
The Scherer U.S. Pat. No. 2,703,047 discloses a similar system of branding 
the filled capsules. 
In the Taylor U.S. Pat. No. 3,124,840, a printing element is provided in 
order to print on the gelatin strip prior to the formation of the capsule. 
The Hansen U.S. Pat. No. 3,203,347 shows a marking fluid that is printed on 
the gelatin ribbon used to make the softgels. 
The Vincent U.S. Pat. No. 3,333,031 shows dying of the gelatin strip before 
capsule formation. 
Even though efforts have been made to manufacture gelatin capsule and 
distinguish them from those of others by using different shapes, sizes, 
colors, color combinations, branding, banding, and printing, there still 
is a need to provide a way to even more uniquely identify one company's 
product from that of another while accomplishing this in a very unique, 
economical, and simplified manner. 
SUMMARY OF THE INVENTION 
It is therefore an important object of this invention to provide a unique 
process and apparatus by which softgels have a fully or partially 
texturized or patterned outer surface prepared in a highly economical way 
by applying a suitable texture to the outer surface of both ribbons, in a 
rotary die process and prior to softgel formulation, so that the softgels 
will be highly distinct from those manufactured by others and where the 
manufacturing process does not involve the use of additional equipment and 
processing steps of the type needed to mark, brand, print, or band 
previously formed capsules. 
It is another object of the present invention to provide a unique method 
and apparatus which involves applying a suitable pattern or texture to the 
outer periphery of a gelatin ribbon used to form a softgel while the 
ribbon is still in a molten or flowable state so as to conveniently accept 
the addition of the desired texture or pattern. 
It is still a further object of the present invention to provide an 
apparatus and process for applying a texture to one or both ribbons of 
gelatin used in the rotary die process used for making softgels wherein 
the apparatus is particularly economical in construction and the method 
utilized is particularly economical in use. 
It is yet a further object of the present invention to provide a unique 
softgel capable of having a texture over its entire surface. 
Further purposes and objects of the present invention will appear as the 
specification proceeds. 
The foregoing objects are accomplished by providing a process and apparatus 
for manufacturing softgels having a patterned or textured surface; the 
process includes the steps of forming a flowable gelatin mass, providing a 
rotary drum having an outer surface, controllably directing the flowable 
gelatin mass to the outer surface of the drum, forming a gelatin ribbon of 
sustantially uniform thickness on the outer surface of the drum, the 
ribbon being initially in a relatively softer or moldable state 
immediately following the directing step, providing a roller with a 
textured surface which is closely adjacent to the outer surface of the 
drum, passing the ribbon while in the relatively soft or moldable state 
between the drum surface and textured surface while applying sufficient 
pressure to the roller towards the drum for causing the textured surface 
to impart a matching texture on the outer surface of the ribbon, providing 
a second gelatin ribbon, forming a plurality of filled softgels from the 
gelatin ribbons while utilizing the conventional rotary die process for 
the manufacture of softgels, the matching texture defining the outer 
surface of at least a portion of the soft gels.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
The rotary die process machine, generally 10, is schematically illustrated 
in FIG. 1. The principal parts thereof include a gelatin metering device 
or spreader box, generally 12, and a gelatin ribbon casting and cooling 
rotary drum 14 upon which the first gelatin ribbon 16 is formed. For 
convenience in illustration, only one spreader box 12 and one rotary drum 
14 are illustrated in FIG. 1. Since the rotary die process uses two 
gelatin ribbons, the second being designated as 18, it is to be understood 
that a similarly situated spreader box (not shown in FIG. 1) and rotary 
drum (not shown in FIG. 1) are utilized in connection with the formation 
of the second gelatin ribbon 18. 
The rotary die process machine 10 further includes a tank 20, generally 
containing a liquid fill material which is any of a wide variety of 
substances both of an edible nature, such as vitamins and pharmaceuticals, 
or of an inedible nature, including oils, bath soaps, and the like. The 
fill material 22 contained in the tank flows to a fill pump 23 which 
meters the volume of the fill material which passes through a line 24 to 
an injection wedge 26. The narrowed lower end of the wedge 26 is 
constructed and shaped to be located between a pair of rotary dies, 
generally 28, which contain matching die pockets 31. The rotary dies 28 
rotate in the direction designated by the arrows 29 shown in FIG. 1. The 
fill material 22 passes through the filling wedge 26 into the space formed 
in the gelatin by the die pockets 31 formed by and between the rotary dies 
28 where the softgels 30 are filled, shaped, hermetically sealed and cut 
from the gel ribbons 16 and 18 using conventional techniques. The filled 
capsules or softgels 30 which are formed are dropped into collecting 
chutes 33 where they fall down onto a conveyor 32. The gelatin net 34 
which remains after the capsules 30 are cut is then passed on for 
collecting and reuse in a known manner. 
The rotary die machine 10, as described, is generally a conventional type 
of machine used for making gelatin capsules or softgels. Although there is 
nothing considered unique in the machine, as described above, it is, 
nevertheless, considered advantageous to have a full understanding of the 
rotary die process in order to have a full understanding of the overall 
process for manufacturing the capsules 30 which have the textured 
appearance as depicted in FIGS. 6 and 7. In FIG. 1, there is no 
illustration of the texturing apparatus, generally 36, which is used for 
applying the textured outer periphery to the outer surface of the gelatin 
ribbons 16 and 18 which have been formed on the rotary casting and cooling 
drums 14. The texturing apparatus 36 which is the general subject of the 
present invention, is best illustrated in FIGS. 2-5. As stated previously, 
the disclosure of the rotary die process in Chapter 13 by Stanley, 
identified above, is incorporated herein by reference. 
Referring to FIGS. 2 and 3, the texturing apparatus 36 is shown in greater 
detail. A machine frame 38 is generally illustrated in FIG. 2, and the 
cooling and casting rotary drum 14 is rotatably mounted about its 
transverse axis 40. The texturing apparatus 36 is mounted closely adjacent 
and below the spreader box 12. Cylindrical outer surface 52 of the 
texturing apparatus 36 is placed sufficiently close to the spreader box 12 
so that the gelatin ribbon 16 or 18 is formed on the outer peripheral 
surface 42 of the drum 14. The texturing apparatus 36 is positioned so 
that the ribbon 16 is in a suitable softened and moldable condition to 
have a suitable texture applied to its exterior surface, that is, the 
ribbon 16 should be sufficiently softened and moldable so as to accept the 
desired textured surface being applied thereto by the texturing apparatus 
36. Referring to FIG. 6, it is seen that the outer surface of the capsule 
30 has a texture of raised ribs 44 provided thereon. It is to be 
understood, however, that the texture for the capsules can vary over a 
wide range. 
A texturing location is generally illustrated in the shaded area 46 as seen 
best in FIG. 2. This area represents a segment of up to approximately 45 
degrees along the outer periphery of the drum 14 and extends from the 
lower, open end of the spreader box 12. If the texturing apparatus 36 is 
positioned beyond the texturing area 46, where the gelatin is applied to 
the outer periphery 42, it is unlikely that the ribbon 16 or 18 will 
accept a texture because the ribbon will have sufficiently hardened on the 
casting and cooling rotary drum 14, which rotates in the direction 
indicated by the arrow 48 in FIG. 2. 
Referring to FIGS. 3-5, the texturing apparatus 36 will be described in 
greater detail. As seen in FIG. 5, a base plate 50 is mounted on the frame 
38 of the rotary die process machine 10. A cross support 54, as best seen 
in FIGS. 4 and 5, is mounted on the base plate 50 at a preselected angle. 
An upright angled rib 56 angularly mounts the cross support 54 to the base 
plate 50. The cross support 54 is elongated and at its opposite ends, has 
a texturing roller assembly 58 operatively mounted at either end thereof 
for the texturing of each ribbon 16 and 18. The roller assembly, generally 
58, includes an elongated roller 60 having a textured outer periphery 62. 
The roller 60 is approximately the same width as the drum 14 and is 
rotatable about the transverse axis 64 which is parallel to the axis 40 of 
the rotary casting and cooling drums 14. Each roller 60 is biased or 
spring mounted towards the drum 14. 
The axis 64, of each roller assembly 60, has the outer ends thereof 
interconnected to a threaded rod 66. Each threaded rod 66 is substantially 
transverse or perpendicular to the axis 64. A retaining washer 68 is 
mounted on the lower end of each of the threaded rods 66. A compression 
spring 70 is positioned between the retaining washer 68 and the cross 
support 54 in such a way that the springs 70 are biased to apply pressure 
in a radial direction, forcing the roller 60 and its peripheral textured 
surface 62 towards or against the outer peripheral surface 42 of the 
casting drum 14. 
Desirably, the pressure applied by the spring 70 is adjustable by the 
adjusting assembly, generally 72, located at the upper end of each of the 
threaded rods 66. Desirably, a spacer 74 is mounted between the cross 
support 54 and the upper retaining washer 74. An adjustment nut 76 is 
threadably mounted at the upper end of the threaded rod so that by 
adjusting the nut 76 along the length of the threaded rod 66, the desired 
amount of pressure can be applied by the spring 70 so the outer textured 
surface 62 of the roller 60 bears towards the outer surface 42 of the 
rotary drum 14 with the ribbon 16 or 18 therebetween. 
In practicing the process for imparting the desired texture to the outer 
periphery of the ribbons 16 and 18, so that a textured outer periphery is 
provided on the capsules 30, attention is directed to the drawings. The 
spreader box 12 is filled with a molten, flowable gelatin of a 
conventional formulation well known to those skilled in the art. The shell 
formulation, generally comprising water, gelatin and a plasticizer passes 
through the spreader box and is applied initially in liquid form against 
the outer periphery of the rotating cooling and casting drum 14. The 
gelatin sheet or ribbon of suitable thickness is desirably placed against 
the outer surface of the drum 14 and upon counterclockwise direction of 
the drum 14, as viewed in FIG. 2, in the direction of the arrow 48, the 
texturing apparatus immediately comes into contact with the outer 
periphery of the gelatin ribbon 16 while it is still in a flowable, or 
moldable condition. 
It is to be understood that the specific condition of the amount of 
pressure applied by the texturing roll against the outer periphery of the 
ribbon is dependent upon an operator of ordinary skill in the art who is 
well capable of setting up the equipment in the proper manner. This is 
considered to be well within the skills of one of ordinary skill in the 
art and is dependent upon a variety of factors, including the nature of 
the shell formulation, ambient conditions, the temperature of the rotary 
drum 14, and the desired thickness to be imparted to the ribbon 16, which 
is dependent upon its end use. Desirably, the outer periphery of the 
roller 60 has a lubricant, such as mineral oil, applied, by suitable 
means, such as a brush (not shown), to its outer surface, in order to 
assure that there is no sticking of the gelatin ribbon to the texturing 
roller 60 once the texture has been applied thereto. The operator adjusts 
the pressure of roller 60 as the ribbon passes between the outer textured 
surface 62 of the roller assembly 58 and the outer peripheral surface 42 
of the casting drum 14. 
As seen in FIG. 1, and as previously described, once the ribbon has been 
formed with the desired texture thereon, it passes around to the rotary 
dies 28 with the wedge 26 therebetween for directing the fill 22 into the 
space between the two ribbons 16 and 18 as they come together between the 
rotary dies 28. 
The capsules 30 thus formed are as illustrated in FIG. 6. In this 
particular capsule, shown in FIG. 6, the capsule 30 has the shape of a 
star and the texture on the outer surface thereof has raised ribs which 
are complementary to the peripheral grooves that are located on the outer 
periphery of the textured surface 62 of the roller 60. In the present 
invention, it is important to have the capability of providing a texture 
over the entire softgel periphery, which was not possible with the prior 
art techniques. Also, it is to be understood that, in certain 
applications, the textured surface can define the inner surface of the 
shell capsule as opposed to the outer surface thereof. It is thus believed 
that all objects previously set forth have been accomplished. 
While in the foregoing there has been provided a detailed description of 
one particular embodiment of the present invention, it is to be understood 
that all equivalents obvious to those of ordinary skill in the art be 
included within the scope of the invention as claimed.