Pre-filling system to eliminate bubbles inside capsules having a solid dosage forms within said capsules

A rotary die mold process for manufacturing softgel capsules incorporating a solid form within said capsule and wherein said softgel capsule is free of air bubbles, the process comprising, that at least two material film strips are brought together by means of counter-running forming rolls and formed into capsules, a liquid and solid filling material being introduced via a distributor plate and filling wedge comprising:

• two concave wedge surfaces;
• inlet channels;
• a system of internal channels;
• a side inlet for injecting prefilling liquid medicine doses for displacing air;
• a top inlet for solid forms;
• a feed chute for both the injected pre-fill liquid medicine and solid forms said feed chute providing spaces for air displacement by the injected prefilling doses and air exits;
• and a feed channel through which solid forms exits;
• wherein when the solid form falls onto the film strip, the film strip separates from the outer wall of the segment, deforming to adapt to the solid form shape profile leading to formation of air chambers trapped between the film strip and the segment;
• synchronizing the process so that injection of prefilled liquid medicine occurs at the instant the film strip separates from the outer wall of the segment, therefore filling the air chambers formed during the film deformation process and allowing said injected prefilled medicine to displace the previously contained air;
• wherein the air displaced by the prefilled medicine vents to the outside through the solid form feed channel and said venting occurs just before the film strip closes the solid form feed channel as the mold rotates;
• and wherein after an upper seal of the capsule is formed, and when the solid form remains inside, a Unigel capsule is obtained without a bubble inside.