1.Shell Composition:
Hard capsules consist of two distinct pieces made primarily from gelatin, often sourced from animal collagen. Gelatin is a protein derived from collagen, typically found in animal connective tissues. This gelatinous material provides the rigid structure of hard capsules. Manufacturers may also use other ingredients in the shell composition to enhance stability or modify release properties, such as plasticizers or coloring agents.
Soft gel capsules, on the other hand, are formed from a single piece of gelatin or alternative polymers. Gelatin remains a common choice due to its biocompatibility and versatility in encapsulating a variety of liquid or semi-solid formulations. Soft gel shells are softer and more pliable compared to their hard counterparts, allowing them to encapsulate materials that are not suitable for hard capsules, such as oils or suspensions.

2.Flexibility:
Hard gel capsules are rigid and inflexible, maintaining their shape even under pressure or stress. This characteristic makes them well-suited for containing dry or powdered formulations, as they provide protection against physical damage or deformation.
Soft gel capsules exhibit flexibility due to their single-piece construction. This flexibility allows them to adapt to the shape of the contents, making them ideal for encapsulating liquids, semi-solids, or suspensions. The soft nature of the shell also facilitates swallowing, making soft gels more comfortable for consumers, especially those with difficulty swallowing solid dosage forms.

3.Manufacturing Process:
Hard gel capsules are typically manufactured using a dip molding process. In this process, stainless steel molds are dipped into a solution of gelatin, which forms a thin layer on the mold surface. The gelatin-coated molds are then cooled and dried to form the capsule halves, which are later joined together to encapsulate the desired formulation.
Soft gel capsules are produced using a rotary die process, which involves continuously rotating molds to encapsulate the liquid or semi-solid formulation within the gelatin shell. This process allows for precise control over the filling volume and ensures uniform encapsulation of the active ingredients.

4.Permeability:
Hard gel capsules offer a low permeability barrier, effectively protecting sensitive ingredients from moisture, oxygen, and other environmental factors. This characteristic makes them suitable for formulations that require enhanced stability and shelf life.
Soft gel capsules have a higher permeability compared to hard capsules, primarily due to their flexible shell composition. While this may make them less suitable for moisture-sensitive or oxygen-sensitive formulations, manufacturers can utilize specialized coatings or barrier materials to mitigate permeability issues and maintain product integrity.

5.Sizes and Shapes:
Hard gel capsules are available in a wide range of sizes and shapes to accommodate various formulations and dosing requirements. Common shapes include cylindrical, spherical, or oblong, with sizes ranging from #000 (largest) to #5 (smallest). Custom shapes can also be designed to meet specific branding or functional needs.
Soft gel capsules typically have a more limited range of sizes and shapes compared to hard capsules. Common shapes include oval or round, with sizes ranging from smaller sizes suitable for pediatric or veterinary use to larger sizes for adult formulations. While customization options may be more limited, manufacturers can still tailor soft gel capsules to fit specific product requirements.

6.Content Types:
Hard gel capsules are primarily used for containing dry or powdered formulations, including vitamins, minerals, herbal extracts, and pharmaceutical actives. The rigid shell provides protection against moisture, oxidation, and physical damage, ensuring the stability and integrity of the encapsulated ingredients.
Soft gel capsules are well-suited for encapsulating liquid or semi-solid formulations, such as oils, suspensions, emulsions, or gel-like substances. This versatility allows for the encapsulation of hydrophobic or lipophilic compounds that may be challenging to formulate in other dosage forms. Soft gels also offer improved bioavailability for certain compounds due to enhanced solubility and absorption.

7.Tamper-Evident Features:
Hard gel capsules often incorporate visible tamper-evident features to provide reassurance to consumers regarding product integrity. These features may include colored bands, printed logos, or snap-fit closures that are visibly damaged upon opening, indicating potential tampering.
Soft gel capsules may lack visible tamper-evident features due to their seamless construction. However, manufacturers typically employ additional packaging measures, such as blister packs or foil seals, to enhance product security and prevent tampering during distribution and storage. These secondary packaging solutions help maintain the safety and authenticity of the product until it reaches the end consumer.