One system for solution batches, dipping runs, laboratory tests and capsule lots.
From customer order to dispatch, the system holds gelatin and polymer receipts, solution batches, dipping and drying runs, printing, sorting, laboratory results and retained samples. Every lot of shells carries its raw material batches, kiln conditions and test figures. Nothing is retyped. A certificate of analysis is built from what was recorded, and the plant answers a filler’s question without opening a notebook.
- Capsule sizes, shell colours and every filler’s limits recorded in the form you use now
- Orders in hand, raw stock and retained samples brought over before go-live
- Later edits to batch sheets and test limits done for you by GullySystem staff
Empty-capsule plants keep orders, raw material lots, solution batches, dipping runs, printing and laboratory tests in one system that GullySystem configures around their own shell sizes. Each lot of shells links to its gelatin or HPMC batch, pigment lot, kiln hours and moisture result. Certificates and packing lists come from recorded figures, with size, colour and print kept per customer.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Order and specification
A filler’s order arrives with size, colour, print and carton count. It is matched to that customer’s stored specification, including test limits and packing rules.
- 2
Solution preparation
A batch is opened with the gelatin or polymer lot, colour and opacifier weights, tank and temperature. Viscosity is entered, and the batch is released only if it is in range.
- 3
Dipping and drying
Dipping runs are logged by machine and pin set, with kiln hours and conditions. Stripped, cut and joined shells are counted against the run.
- 4
Printing and sorting
Printed lots record the artwork version and ink lot. Sorter and visual inspection output is entered by defect type.
- 5
Laboratory release
Samples are tested for moisture, lock length, wall thickness and disintegration. Results are read against the customer’s limits, and the lot is released or held.
- 6
Packing and dispatch
Approved shells are packed in lined cartons with lot labels. The certificate, packing list and invoice go out together, and a retained sample is shelved.
What is inside.
Every module can be switched on, left out or changed to match how your team already works.
The business modules it is built from.
Each one is also available on its own, or inside a system built for you.
- Batch and Serial Tracking
Each solution batch links its gelatin, colour and opacifier lots to the dipping runs it fed and the shell lots that result.
- Product Management
A master for every size, colour and print holds the filler’s test limits and packing format, so orders open against current rules.
- Quality Control
Moisture, lock length and wall thickness are read against each customer’s limits, and a failure places the lot on hold.
- Goods Receipt (GRN)
Gelatin and polymer deliveries are received by supplier lot with the analysis attached, and a lot under test is blocked from issue.
- Work Order Management
Each run is released to a dipping machine with size, colour and pin set, and operators log output and kiln hours against it.
- Stock Tracking and Alerts
Pigment and opacifier balances show by lot and expiry, with an alert before a planned colour change lacks material.
- Document Management
Certificates of analysis and packing lists attach to the lot and customer, so any shipped document can be reproduced later.
- Barcodes and Labels
Lot labels for cartons and retained samples are printed with lot, size and colour, and scanning finds the shelf location.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For plant heads
Read lots in process, lots on hold, yield by size and machine, and open orders by filler without walking the shop.
For solution and dipping operators
Open the batch sheet for the shift, enter weights, temperatures and run output, and see which pin set is due for change.
For quality and laboratory staff
Test against each customer’s limits, place a lot on hold, and release it with a signed result that prints on the certificate.
For stores and dispatch
Receive gelatin and polymer deliveries, shelve retained samples, label shell cartons by lot and print every packing list.
The numbers the owner asks for.
- Yield by size, colour and dipping machine
- Reject counts by defect type and pin set
- Lots on hold with the failed parameter
- Raw material lots with expiry and balance
- Moisture and lock length trend per customer and size
- Retained samples by lot and shelf
- Orders open against promised dispatch dates
Who this is built for.
- Plants that make empty hard gelatin capsules for pharmaceutical fillers
- Makers of HPMC or pullulan shells for vegetarian and supplement brands
- Capsule plants that print logos and bands on shells
- Manufacturers that sell several sizes and colours to many filling customers
- Plants whose customers audit lot records and ask for certificates
When it is not the right choice.
- A plant that only fills capsules for others will find the contract or nutraceutical products closer.
- A trading business that buys empty shells and resells them needs stock and sales tools, not batch records.
Adapted to your business before it goes live.
You are not handed a login and left to it. The product is set up around your records, your people and the tools you already use.
Works alongside
- WhatsApp or other messaging
- Accounting export
- Barcode labels
- Laboratory instrument export
Questions owners ask before a demo.
Can I see which gelatin lot went into a lot of size 0 shells?
Yes. Open the finished lot, follow it to the dipping run, then to the solution batch. The gelatin, colour and opacifier lots are listed with their weights.
Does it work for HPMC and pullulan shells?
It does. Plant-based shells use the same solution, dipping and test records, with their own parameters and limits entered during set-up.
Can limits differ for each filler?
Yes. Lock length, moisture, wall thickness and print rules are stored by customer and size. The laboratory sees the right set when a lot is sampled.
Will it replace the control charts on the kilns?
No. Charts and data loggers stay where they are. The software records the readings you enter or import for each run and ties them to the lot.
What happens to a lot that fails lock length?
The lot is placed on hold, the quality head is notified and the shells cannot be packed. Release needs a signed decision, which stays on the record.
How are retained samples handled?
Each sample is logged against its lot with a shelf location and a discard date. A search by lot or customer returns where it sits.
Can the certificate show our own layout?
The certificate is built from recorded results in a layout agreed during set-up. Customer-specific wording is added per filler.
Can our current shell sizes and stock figures be brought in?
Sizes, colours, customers and open stock come across from spreadsheets during set-up. Old lot history is brought over to the depth you choose.
What does a plant of our size pay?
Pricing rests on the count of dipping machines, laboratory logins and how much lot history you carry forward. We run a demo with your own sizes first, and a quotation follows it.
Who looks after changes once it is live?
GullySystem staff handle edits to batch sheets, limits and certificate layouts when you ask. Your quality head approves each change before it goes live.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Capsule Manufacturer Management Software with your own data.
Tell us how you run things today. We’ll show you the parts that matter to you and say plainly what would need changing.
- No obligation
- A reply within one business day
- Your details stay private
Start with your requirements
Seven short steps that tell us what you need. An engineer reads them before getting in touch.
Share your requirements