Soft Gelatin capsules: Quality control testing is essential in the manufacturing of soft gelatin capsules to ensure the product meets pharmacopeial specifications, maintains its integrity throughout its shelf life, and delivers the intended therapeutic effect. Quality control (QC) procedures are divided into two main phases: in-process testing and final product testing. Both phases are critical and serve different but complementary roles in assuring product quality.
Soft Gelatin capsules
1. In-Process Quality Control Tests
In-process quality control (IPQC) refers to tests conducted during the various stages of manufacturing to monitor the process and make necessary adjustments in real time. These tests help detect deviations before the batch progresses to the next stage, thus preventing the production of substandard capsules.
1.1 Gel Mass Parameters: The first stage in softgel production is the preparation of the gelatin mass. During this phase, the key in-process checks include monitoring viscosity, temperature, and pH of the gelatin solution. Viscosity is critical for uniform capsule shell formation, and pH must be within an acceptable range (typically 4.5–5.5) to avoid gelatin degradation.
1.2 Fill Material Checks: The fill matrix, whether it is a liquid, semi-solid, or suspension, must be monitored for homogeneity, density, viscosity, and absence of air bubbles. If the fill contains suspended drugs, frequent stirring and sampling are necessary to maintain uniformity. Also, microbial limits are often assessed if the formulation contains water or is susceptible to contamination.
1.3 Encapsulation Monitoring: During the encapsulation step, several parameters are checked:
- Sealing Quality: Capsules must be well sealed at the seam to prevent leakage.
- Shell Thickness and Ribbon Temperature: Shell thickness is verified using micrometers. It usually ranges between 0.6 mm to 1.2 mm. Ribbon temperature is also monitored to ensure proper formation of the capsule.
- Fill Weight and Weight Variation: Random capsules are collected from the run to measure the fill weight using a balance. Weight variation is assessed to ensure dosage uniformity.
- Rotary Die Speed and Timing: The encapsulation machine settings such as die roll speed and timing between fill injection and ribbon sealing are optimized and checked regularly.
1.4 Strip Sealing and Drying Controls: After encapsulation, the capsules pass through a tumble dryer and tray dryer. At this stage, drying temperature, time, and humidity are monitored. Improper drying can lead to shell brittleness or capsule deformation.
2. Final Product Quality Control Tests
Final product testing is conducted on capsules after completion of manufacturing and prior to release. These tests ensure the product complies with pharmacopeial standards (e.g., USP, IP, BP) and customer specifications. The major quality parameters assessed include:
2.1 Organoleptic Properties: The capsules are examined for color, odor, size, shape, and absence of physical defects such as cracks, leakage, stickiness, or deformation. Any variation in appearance may indicate formulation issues or process failure.
2.2 Weight Variation Test: This test determines if each capsule contains the correct amount of fill material. A sample of intact capsules is weighed, then carefully cut open and the fill removed. The empty shells are reweighed to calculate the net fill weight. The variation must be within ±10% of the average weight for compliance.
2.3 Disintegration Test: This test evaluates how quickly the capsule breaks down in a simulated gastrointestinal environment. Softgel capsules are usually tested in 37°C water or simulated gastric fluid (SGF). The disintegration time must comply with pharmacopeial requirements—typically, capsules should disintegrate within 30 minutes unless otherwise specified.
2.4 Dissolution Test: The dissolution profile is a key indicator of drug release behavior. Using USP Apparatus I (basket) or II (paddle), capsules are placed in a dissolution medium (like 0.1 N HCl, phosphate buffer, etc.) and the percentage of drug released is measured over time. A minimum of 80% drug release in 45 minutes is a common criterion, but specific drugs may have different standards.
2.5 Content Uniformity: This ensures that the active pharmaceutical ingredient (API) content in each capsule falls within the acceptable range (typically 85%–115% of the label claim). Ten capsules are assayed individually by HPLC, UV spectrophotometry, or another suitable method. This test is particularly important for low-dose drugs.
2.6 Leakage and Sealing Integrity Test: Capsules are subjected to mechanical stress, temperature variations, or vacuum testing to detect any leaks. A dye penetration test may also be performed where capsules are submerged in a colored solution under vacuum to check for dye ingress.
2.7 Moisture Content: Soft gelatin shells are hygroscopic, and excessive moisture can compromise capsule integrity and stability. A Karl Fischer titration or loss on drying (LOD) method is used to determine moisture content. Ideal values typically range from 6% to 10%.
2.8 Microbial Limit Test: The final product is tested for microbial contamination. This includes total aerobic microbial count (TAMC), total yeast and mold count (TYMC), and the absence of specified pathogens like E. coli, Salmonella, Staphylococcus aureus, and Pseudomonas aeruginosa as per pharmacopeial guidelines.
2.9 Stability Testing: Although not part of routine batch release, selected batches undergo stability testing under ICH-recommended conditions (e.g., 25°C/60% RH, 40°C/75% RH). Parameters like appearance, drug content, disintegration, and dissolution are evaluated at scheduled intervals to predict shelf life and storage requirements.
Conclusion
In summary, quality control testing—both in-process and final product—is essential to the manufacturing of soft gelatin capsules. In-process tests focus on controlling the parameters that affect capsule formation, fill uniformity, and drying efficiency, allowing real-time corrections. Final product tests ensure that the finished capsules meet all safety, efficacy, and stability requirements. Together, these quality control measures ensure that each capsule batch is consistent, therapeutically effective, and safe for patient use. They also facilitate compliance with regulatory standards and good manufacturing practices (GMP).