Gelatin capsule formulation and drying system

A method of drying gelatin capsules encapsulating a fill, the method comprising the steps of:

• dividing a space into first, second and third zones,
• providing a first air handler unit for discharging air into the first zone, wherein the first zone includes a first temperature sensor and a first humidity sensor that are both in communication with the first air handler unit,
• a second air handler unit for discharging air into the second zone, wherein the second zone includes a second temperature sensor and a second humidity sensor that are both in communication with the second air handler unit, and
• a third air handler unit for discharging air into the third zone, wherein the third zone includes a third temperature sensor and a third humidity sensor that are both in communication with the third air handler unit,
• providing air to the first air handler unit at a first temperature and a first relative humidity, wherein the air within the first air handler unit is conditioned such that it has a second temperature and a second relative humidity, wherein the conditioned air is blown from the first air handler unit into the first zone,
• providing air to the second air handler unit at the first temperature and the first relative humidity, wherein the air within the second air handler unit is conditioned such that it has a third temperature and a third relative humidity, wherein the conditioned air is blown from the second air handler unit into the second zone,
• providing air to the third air handler unit at the first temperature and the first relative humidity, wherein the air within the third air handler unit is conditioned such that it has a fourth temperature and a fourth relative humidity, wherein the conditioned air is blown from the third air handler unit into the third zone,
• providing a series of tumble dryers that extends from the first zone, through the second zone and into the third, and
• drying the gelatin capsules by moving the gelatin capsules through the tumble dryers from the first zone to the third zone.

A method of drying a softgel, the method comprising the steps of:

• providing air from an HVAC unit to first, second and third air handler units, wherein the first, second and third air handler units are in communication with first, second and third control panels, respectively and can each blow air therefrom, and wherein the HVAC unit, first air handler unit, second air handler unit and third air handler unit are all controlled independently,
• exposing the softgel to the air blown from the first air handler unit,
• exposing the softgel to the air blown from the second air handler unit, and
• exposing the softgel to the air blown from the third air handler unit.