Soft Gelatin Facility

A Global-Scale Facility for Softgel Manufacturing

The OneSource SoftCaps facility, supporting specialized softgel encapsulation and vegan softgel manufacturing, is purpose-built to deliver high-volume production of complex oral dosage forms, combining formulation expertise with advanced encapsulation and inspection technologies.

Spanning more than 60,000 square feet and supported by over three decades of experience, the site enables efficient progression from development through commercial manufacturing, with the scale and consistency required for global supply.

Built for Scale, Flexibility, and Continuous Production

The facility is designed to support large-scale manufacturing across a wide range of softgel formats, with an annual production capacity of approximately:

  • 2.4 billion capsules per year
  • Multiple encapsulation lines, including dedicated prescription product capacity
  • Flexible batch sizes supporting both clinical and commercial supply

This scale allows OneSource to support both high-demand commercial products and specialized formulations requiring controlled production environments.

Explore SoftCap Capabilities

Advanced Encapsulation and Manufacturing Infrastructure for Specialized Softgel Encapsulation

SoftCap production requires precise coordination across formulation, encapsulation, drying, and inspection. The facility is equipped with advanced rotary die encapsulation systems, supported by long-standing technical collaboration with Pharmagel, Italy.

These systems are designed to ensure consistent capsule integrity, uniform fill, and reliable performance across large production volumes.

Core manufacturing capabilities include:

  • Multi-line encapsulation for diverse product types
  • Dedicated production lines for regulated prescription products
  • Controlled drying and curing environments
  • Integrated printing, inspection, and packaging systems

Automation, Inspection, and Process Control

Automation is central to achieving both scale and consistency in softgel manufacturing.

The facility integrates advanced inspection and control technologies, including:

  • High-speed printing systems with camera-based inspection
  • Automated lubrication and inspection through in-house Symetix systems
  • Minimal manual intervention across critical production steps
  • Real-time monitoring and data-driven process control

This approach reduces variability, improves yield, and ensures consistent product quality across batches.

Supporting a Wide Range of SoftCapFormats

The facility is capable of producing a diverse range of SoftCap formats to meet different therapeutic and patient needs.

  • Immediate-release and delayed-release softgels
  • Enteric-coated capsules for targeted delivery
  • Chewable and patient-friendly dosage forms
  • Applicaps and suppository formats
  • Capsules across multiple shapes, sizes, and fill types

This flexibility enables tailored solutions across both pharmaceutical and nutraceutical applications.

Integrated Packaging and Supply Chain Capabilities

Beyond manufacturing, the facility supports a full range of packaging and distribution requirements.

Capabilities include:

  • Bulk, bottle, and blister packaging configurations
  • Serialization-ready packaging lines
  • Integrated warehousing and inventory management
  • Cold chain storage and validated shipping solutions

These capabilities ensure that products are not only manufactured efficiently, but also prepared for reliable global distribution.

Quality and Compliance at Global Standards

The softgel facility operates under stringent cGMP conditions, with quality systems embedded across all stages of production.

The site has been inspected and approved by multiple global regulatory authorities, supporting supply into highly regulated markets.

Regulatory approvals include:

  • US FDA
  • ANVISA
  • Health Canada
  • TGA
  • EMA
  • MHRA
  • WHO
  • MCC

Designed for Reliable, High-Volume Execution

With a combination of scale, automation, and technical expertise, the facility is built to deliver consistent output across demanding production schedules.

This enables:

  • Reliable commercial supply for high-volume products
  • Efficient scale-up from development programs
  • Flexibility to support multiple product types simultaneously

The result is a manufacturing platform capable of meeting both performance and supply chain expectations in today’s market.

High-Volume, High-Precision Softgel Production

KRS Gardens, No.36/7,
Suragajakkanahalli, Anekal Taluk, Karnataka 562106, India

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