Softgel capsule mold sizes play a critical role in the pharmaceutical, nutraceutical, and dietary supplement industries. The mold determines the capsule’s fill volume, shape, dimensions, and sealing quality, directly impacting dosage accuracy, production efficiency, and consumer experience.

This guide provides a comprehensive overview of softgel capsule mold sizes, including standard size tables, common shapes, and selection considerations to help manufacturers and product developers choose the right mold for their formulation.

What Are Softgel Capsule Mold Sizes?

Softgel capsule mold sizes refer to the engraved cavity dimensions in rotary die rolls used during softgel encapsulation. These cavities define:

• Capsule volume (mL / cc)
  
  

• Capsule shape (oval, oblong, round, tube)
  
  

• Length, width, and thickness
  
  

• Seam geometry and wall strength
  
  

Softgel mold sizes are commonly specified in milliliters (mL or cc) or minims, depending on industry convention.

Why Softgel Mold Size Selection Is Important

Choosing the correct softgel mold size is essential for:

• Accurate dosage delivery
  
  

• Consistent capsule appearance
  
  

• Efficient encapsulation speed
  
  

• Improved consumer swallowability
  
  

• Regulatory compliance
  
  

Incorrect mold sizing can lead to underfilling, overfilling, poor seals, or production inefficiencies.

Common Softgel Capsule Shapes

Softgel molds are available in multiple standardized shapes, each offering specific advantages:

• Oval Softgels – Most widely used; balanced volume and swallowability
  
  

• Oblong Softgels – Longer profile; suitable for higher fill volumes
  
  

• Round Softgels – Compact and symmetrical; often used for small or large doses
  
  

• Tube Softgels – Elongated design; used for specialty or cosmetic applications

Standard Softgel Capsule Mold Size Tables

Below are industry-standard softgel mold size references commonly used by softgel manufacturers worldwide. Volumes may vary slightly depending on formulation density and gelatin shell thickness.

Oval Softgel Capsule Mold Sizes

Oblong Softgel Capsule Mold Sizes

Round Softgel Capsule Mold Sizes

Tube Softgel Mold Sizes

How to Choose the Right Softgel Mold Size

When selecting a softgel capsule mold size, consider the following factors:

1. Dosage and Fill Volume

Match mold volume to the required dose, accounting for excipients and density.

2. Fill Material Properties

Viscosity and temperature sensitivity influence fill accuracy and mold performance.

3. Consumer Swallowability

Smaller or elongated shapes improve user compliance.

4. Encapsulation Machine Compatibility

Ensure mold size aligns with rotary die equipment specifications.

5. Regulatory and Market Expectations

Certain regions and product categories favor specific capsule sizes.

Custom Softgel Capsule Mold Sizes

Custom softgel molds are often developed for:

• Brand differentiation
  
  

• Unique dosage requirements
  
  

• Specialized pharmaceutical or cosmetic applications
  
  

Custom mold design allows optimization of appearance, performance, and production efficiency, but requires engineering validation and tooling expertise.

Conclusion

Softgel capsule mold sizes directly influence product quality, manufacturing efficiency, and consumer acceptance. By understanding standard mold sizes, shapes, and fill volumes, manufacturers can make informed decisions that reduce development time and improve production outcomes.

Whether producing small pharmaceutical softgels or large nutraceutical capsules, selecting the right mold size is a foundational step in successful softgel manufacturing.