In the first stage, the composition must be checked for bacterial contamination. Technicians dissolve and add the raw materials into petri dishes and incubate them for 72 hours, allowing any existing bacteria to grow. After incubation, samples are taken and examined under a microscope to determine if they are sterile. Once the materials pass this stage, a spectrometer is used to detect whether the raw materials contain heavy metals such as lead, mercury, or cadmium. The raw material solution is injected into a plasma flame, and the wavelengths of the emitted light are measured to analyze the chemical components of the solution. If the materials pass this test, they can proceed to the next stage.
Softgel capsules are made entirely from natural ingredients: gelatin derived from bovine bones, palm oil-based glycerin, and purified water. An industrial mixer combines the three ingredients in a proprietary ratio, mixing them evenly and heating the mixture to 79.4°C. The resulting gel mass flows into a storage tank and is placed under vacuum. Meanwhile, workers prepare the medication for filling. Using vitamin D as an example, the factory mixes it with soybean oil and adjusts it to the specified potency. To prevent the gel from solidifying, the storage tank maintains the gelatin mixture at 60°C, and the pipes connected to the container are wrapped with heating bands.
Once the medication is prepared, it is transported through a pipe to the same production area. This pipe does not require heating, as the mixture of vitamin D and soybean oil does not solidify when cooled. On the production line, two workstations simultaneously spread a layer of melted gel onto chilled drums. The gel solidifies into flexible sheets. These sheets pass through a rotary die equipped with capsule-shaped cavities. As the two gelatin sheets meet, another machine injects a precise dose of the vitamin D solution into the cavities. The machine then heats the gelatin sheets to bond them together, forming complete capsules. The capsules are cut off and sent along a conveyor belt into a tumbler, where they undergo three hours of cool air drying. In the final stage, they are dried for an additional 36 hours before being packaged and shipped.
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