When is necessary to invest a new set softgel die roll mold tooling, this article will make analysis from user manufacturing side, when practical need.

BLACK AREA ON SURFACE OF DIE ROLLER

Like below photo, such black area in cavity surface or anywhere else of the die roll, its normal after the die roller used for some time, its caused by improper cleaning and drying. User can continue to use it if it has no any effect to the softgel encapsulation performance; while if effect exists, such black area is not able to repair, and it can not be used any more, a new set should be invested.

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UNEVEN RAGGED POINTS ON SURFACE OF CAVITY EDGE

As previous article introduced, the die roller must be handled very carefully, we can say it should be treated like a new baby, so to have it brand new even after every time using and cleaning, with longer service life and better performance during using. 

When a new set die roller, the surface of everywhere on die roll must be smooth, user can touch the surface by hand and prove this smooth, such smooth surface can make sure the easy released of the formed capsule and the good seaming of every soft capsule.

The reason lead to such uneven ragged points on surface of cacity edge, its not only one, mainly from:

• Improper cleaning
• Unclean impurities in the gelatin liquid
• Not well alignment between die roller and main machine

Because every alignment there will be some deviation, its important to make alignment every time well enough.

INJECTION WEDGE LOOSING ITS COAT

To see how many coat is fall off, if not serious, it can be repaired, to have only the injection wedge recoating; if serious, its not suggested to do recoating. Injection wedge loosing its coat, it will have the bad seal of soft capsule and make soft capsule shape not good.

ARTIFICIAL DAMAGE

It seems artificial damage will not happen for such die roll tooling, but it happens very often for any factories. For example, one screw or foreign matter entering in which makes the die roller deformed.

BACKUP WHOLE SET OR INJECTION WEDGE

Its normal that most users choose to buy 2 sets at once, one for production, another for backup, considering the capacity and service life, roller and injection wedge are easy damaged parts, so to make sure the continuous production without stop.

AFTER 0.1 BILLION SOFT CAPSULE OUTPUT

As our previous article introduced, its much better to invest a new set softgel die roll tooling after output of 0.1 billion capsules, so to keep the high performance and good seal and well released. During the roller working, two rollers squeeze to each other and cavity edge will cut the gelatin often to release the formed capsule, after some time using, hardness and strength of roller will be less and damaged.

BAD SEALS LEAD TO LEAKING SOFTGEL

Leaking softgel is very typical problem for all factories users, its caused by bad seal of soft capsule. But to solve the bad seals, softgel tooling factor is only one of them, mostly the factors would be:

• Softgel die roll tooling structure design
• Injection wedge timing operation
• Service life, softgel die roll tooling damage after some time using

So when leaking softgel, we shall combine the actual production condition and maky analysis to solve from every factors, so to make sure no any one leaking softgel happen again.

If we only make analysis from the output soft capsule, time to consider a new softgel die roll tooling set invest when below phenomenon happening:

• Experiencing bad seals resulting in leaking soft capsules
• Not easy released for the formed soft capsule
• Low RPM output
• Bubble in soft capsule