Method and apparatus for the manufacture of softgels

Abstract

Provided is a die roll for manufacturing softgels, a softgel, and methods for producing a softgel. The die roll includes a die roll surface and a pocket defined therein. The pocket includes a floor, an interior sidewall surface, a chamfer, and an exterior sidewall surface. The floor is recessed relative to the die roll surface and the interior sidewall surface is connected to the floor and extends above the die roll surface to the chamfer. The pocket also includes a landing surface that is elevated from the die role surface and connects the chamfer to the exterior sidewall surface of the pocket. The landing surface includes a taper (such that the landing surface tapers inwardly towards the pocket floor) and a radius (such that the landing surface is not flat). Also provided is a softgel having a trailing edge thickness that is at least about 40% the thickness of the softgel wall thickness.

What is claimed is: 
     
         1 . A die roll, comprising:
 a die roll surface;   a pocket, the pocket comprising a floor, an interior sidewall surface, a chamfer, and an exterior sidewall surface, the floor being recessed relative to the die roll surface and the interior sidewall surface being connected to the floor and extending above the die roll surface to the chamfer;   a landing surface, the landing surface being elevated from the die role surface and connecting the chamfer to the exterior sidewall surface of the pocket, wherein the landing surface is tapered inwardly towards the pocket floor and forms a boundary of the pocket.   
     
     
         2 . The die roll of  claim 1 , wherein the landing surface forms a boundary defining a shape of the pocket. 
     
     
         3 . The die roll of  claim 2 , wherein the shape is a heart shape. 
     
     
         4 . The die roll of  claim 1 , wherein the landing surface comprises an interior edge and an exterior edge. 
     
     
         5 . The die roll of  claim 4 , wherein the exterior edge of the landing surface is elevated between about 4.0 to about 10.0 thousandths of an inch above the interior edge. 
     
     
         6 . The die roll of  claim 5 , wherein the elevation the exterior edge of the landing surface above the interior edge forms the inward taper. 
     
     
         7 . The die roll of  claim 1 , wherein the landing surface is tapered inwardly at an angle of at least 7 degrees. 
     
     
         8 . The die roll of  claim 1 , wherein the chamfer comprises a chamfer floor and a chamfer wall, the chamfer floor being about 5.0 thousandths of an inch in length and the chamfer wall being about 5.0 thousandths of an inch in length. 
     
     
         9 . The die roll of  claim 8 , wherein the chamfer further comprises a chamfer notch that is located between the chamfer floor and the chamfer wall. 
     
     
         10 . The die roll of  claim 1 , wherein the landing surface comprises a rounded surface. 
     
     
         11 . The die roll of  claim 10 , wherein the rounded surface comprises a region that bows outwardly away from the die roll. 
     
     
         12 . An apparatus for manufacturing a softgel, the apparatus comprising:
 a first die roll and a second die roll, the first and second die roll being mated to each other and the first die roll and the second die roll each comprising a die roll surface, a plurality of pockets, and a plurality of landing surfaces,
 wherein each pocket of the first and second die roll comprises a floor, an interior sidewall surface, a chamfer, and an exterior sidewall surface, the floor being recessed relative to the die roll surface and the interior sidewall surface being connected to the floor and extending above the die roll surface to the chamfer; and, 
 wherein each landing surface of the first and second die roll is elevated from the die role surface, thereby connecting the chamfer to the exterior sidewall surface of the pocket, the plurality of landing surfaces being tapered inwardly towards the pocket floor thereby forming a boundary of the pocket. 
   
     
     
         13 . The apparatus of  claim 12 , wherein each landing surface forms a boundary defining a shape of the pocket. 
     
     
         14 . The apparatus of  claim 13 , wherein the shape is a heart shape. 
     
     
         15 . The apparatus of  claim 12 , wherein each landing surface comprises an interior edge and an exterior edge, the exterior edge of the landing surface being elevated above the interior edge. 
     
     
         16 . The apparatus of  claim 15 , wherein the elevation the exterior edge of the landing surface above the interior edge forms the inward taper. 
     
     
         17 . The apparatus of  claim 12 , wherein each landing surface is tapered inwardly at an angle of at least 7 degrees. 
     
     
         18 . The apparatus of  claim 12 , wherein the chamfer comprises a chamfer floor and a chamfer wall, the chamfer floor being about 5.0 thousandths of an inch in length and the chamfer wall being about 5.0 thousandths of an inch in length. 
     
     
         19 . The apparatus of  claim 18 , wherein the chamfer further comprises a chamfer notch that is located between the chamfer floor and the chamfer wall. 
     
     
         20 . The apparatus of  claim 18 , wherein each landing surface comprises a rounded surface, the rounded surface bowing outwardly away from the die roll.