Softgels — the format for oil-active stacks and lipid-soluble vitamins.
Gelatin or plant-based shell options, project-managed inside the quality-controlled supply chain.
- Working routes
- Semi-custom · Custom
- Documentation
- 4 gates by project stage
- Target markets
- EU · UK · US
- Working routes
- 3
- Documentation gates
- 4
- Target markets
- EU · UK · US
white-label · semi-custom · custom.
brief · spec · artwork · release.
reviewed per market framework.
Softgels are the definitive format for oil-actives — omega-3, vitamin D, CoQ10, MCT-based stacks. The fill chemistry is reviewed before spec lock so what ships matches what was promised.
When softgels fit
Softgels are right when the active is lipid-soluble or oil-based, when the brand needs a premium clinical SKU, or when the active dose would oxidise in a non-protected format.
- Omega-3 and lipid-soluble vitamin ranges (D, E, K, A).
- CoQ10, astaxanthin and other oil-carried bioactives.
- Premium clinical SKUs where oil-active protection and bioavailability are the priority.
How softgels are made
A softgel is an encapsulated oil or oil-suspension fill held inside a one-piece gelatin or plant-based shell formed and sealed in a single rotary-die step. Shell options include bovine or fish gelatin, and plant-based shells built from modified starches and carrageenans for vegan positioning. Fill is the spine of the format: omega-3 fish oil and algal oil for DHA/EPA stacks, MCT-carrier vitamin D₃, vitamin E, vitamin K, vitamin A, CoQ10, astaxanthin, lutein, sea-buckthorn oil and other lipid-soluble bioactives. Active dose is driven by fill volume, which in turn drives softgel size and shape (oval, round, oblong, twist-off). Standard finish options include enteric coating for fishy after-taste mitigation, printed identification, and twist-off configurations for liquid extracts. Payload is wide for oil-actives but constrained for water-soluble actives — softgels are the wrong choice for B-vitamin stacks or mineral salts that perform better in a hard-shell capsule. Brands choose softgels when the active is lipid-soluble or oil-carried, when oxidation protection matters, or when the SKU sits at the premium end of a clinical range alongside a capsule daily-use.
Pick the route that matches the brief.
Every project moves through one of three routes. Final routing is confirmed inside the portal — the route shapes the documentation set and the timeline.
Reviewed concept, brand artwork.
Pick a reviewed concept from the catalogue and adapt brand artwork. The fastest path from brief to launch — packaging, claims and documentation are reviewed against the target market.
- Best for
- First SKU · short timelines
- Lead time
- Confirmed in the quote
Adjusted within an existing matrix.
Adjust dose, flavour or active stack within an existing matrix. Differentiate the SKU without a full custom-development cycle. Documentation route follows the same project gates.
- Best for
- Differentiated SKU · existing brand
- Lead time
- Confirmed in the quote
Bespoke formulation and dieline.
Fully bespoke formulation, custom flavour profile and packaging dieline. The right route for category-defining launches with longer planning windows and committed quantities.
- Best for
- Category-defining launch · committed quantities
- Lead time
- Confirmed in the quote
What each route looks like for softgels
White-label availability is reviewed per project. The fill chemistry sits inside the spec, so true white-label is usually limited to canonical reviewed concepts (omega-3, vitamin D₃, CoQ10) where the brand can adopt the spec directly. DAT confirms availability in the brief.
Semi-custom is the typical softgel route: a reviewed fill adjusted for the brand — dose tier, shell choice (gelatin vs plant-based), softgel size and shape, or a co-active added within compatible chemistry. First runs land at the 2,500-unit MOQ tier and DAT confirms feasibility before spec lock.
Custom softgel development covers novel oil-actives, multi-active premium stacks, bespoke shell systems and specialised formats (twist-off liquid extracts, enteric coatings, premium fish-oil concentrates). First runs land at the 5,000-unit MOQ tier and timelines are confirmed per project after the fill feasibility review.
PET bottle · Blister
Softgel packaging is confirmed per project — PET bottle is canonical; blister suits pharmacy-channel SKUs.
Softgel packaging is reviewed against the channel and shelf-life claim. PET bottle is canonical for daily-use ranges — 30, 60 or 90-day counts, child-resistant or standard caps, induction-sealed liners and a tamper-evident outer where the channel calls for it. Blister packs suit pharmacy-channel SKUs and premium clinical positioning; aluminium-aluminium blister provides the strongest moisture and oxygen barrier for oxidation-sensitive oil-actives. Outer cartons and shipping configuration are reviewed alongside the inner pack.
- PET bottle
Canonical supplement-shelf format for 30/60/90-day daily-use ranges.
- Blister
Pharmacy-channel premium presentation.
- PET bottle (30/60/90-day)
- Blister pack (PVC / Alu-Alu)
- Amber bottle (light-sensitive oils)
- Tamper-evident induction seal
- Child-resistant cap
- Premium outer carton
- Desiccant liner
- On-pack QR / batch code
Reviewed concepts for this format
A short pick of reviewed concepts. Final positioning, claims and documentation are confirmed per project.
-
Omega-3 fish-oil softgel
Daily-use oil-active in the canonical softgel format.
-
Plant-based vitamin D₃ softgel
Vegan-shell softgel with lipid-soluble vitamin D₃.
-
CoQ10 softgel
Premium cardiovascular-positioning softgel.
Top actives for softgels
Ingredients commonly reviewed for this format. Open a dossier to see dose anchors, working forms and formulation notes.
Other formats in the solid dosage group
Adjacent manufacturing formats DAT supports across the same product family.
Common actives for this format
Frequently asked questions
Are plant-based softgel shells available?
Yes — plant-based shells are routine alongside gelatin. Shell choice is confirmed during the brief against the active list.
Why a softgel rather than a capsule?
Softgels protect oil-active and lipid-soluble actives that would not perform inside a hard-shell capsule. Active selection drives the format choice.
Is white-label available for softgels?
Softgels typically route through semi-custom or custom because the fill chemistry is part of the spec. White-label availability is confirmed per project.
What documentation gates apply?
Brief review, spec confirmation, artwork review per the target-market framework, and batch-specific Certificate of Analysis after QC release.
What is the order of magnitude for a first run?
Semi-custom starts from 2,500 units; custom development from 5,000 units. Final volumes are confirmed in the quote.
Continue exploring
Private-label framing, related formats and the public-ready catalogue.
- Private label
Private label softgels →
Reviewed concepts in this format, pivoted for the private-label brand owner. Same four-gate documentation route, catalogue-led.
- Related format
Capsules manufacturing →
Hard or vegetarian capsule format. Reviewed per project; documentation route follows the standard project gates.
- Related format
Tablets manufacturing →
Compressed tablet format. Reviewed per project; finish (uncoated, film-coated, chewable) confirmed during the brief.
- Catalogue
Browse softgels concepts →
Every public-ready PIM concept detected as softgels, sorted by family for quick scanning.
Request a softgel quote
Send the brief — DAT will confirm shell choice, review fill chemistry and frame the spec lock.