Rotary Die Encapsulation CDMO — Europe
Europe's Premier Industrial
Softgel Contract Manufacturer.
Three independent industrial-scale rotary die encapsulation lines with over 100 million capsule monthly capacity. Zero QA complaints across 17 years and 350+ global brand deployments. Gelatin and HPMC plant-based softgels for omega-3, CoQ10, vitamin D, and complex botanical formulas.
About Olympia Biosciences™
International Organic Company
Founded in 2009 and operating from a state-of-the-art manufacturing facility in Poland, Olympia Biosciences™ is a Contract Development and Manufacturing Organization with 17 years of verified expertise serving the global nutraceutical and pharmaceutical sectors. Our facility specialises in the highly scalable production of softgel capsules, hard capsules, and specialised cosmeceuticals.
Zero Conflict Policy
Olympia Biosciences™ operates under a strict "Zero Conflict" policy — we do not own or develop any B2C proprietary brands. Your Intellectual Property remains 100% yours, protected by a partner with no competitive agenda.
Infrastructure
Pharmaceutical-Grade Softgel Supply Chain Resilience
Most contract manufacturers operate a single softgel line. When it requires maintenance, your launch is delayed. We operate three independent, high-speed rotary die lines with 300% technical redundancy.
No Queue Bottlenecks
Parallel production across 3 independent lines eliminates the single-line bottleneck. We process single batches from 5 million to 20+ million capsules without interrupting other projects.
Dedicated Line Allocation
Your product runs on a dedicated line — no cross-contamination risk, no shared changeover time with other clients' formulations.
Scale Without Switching
From 50,000 pilot capsules to 50 million production run — same facility, same team, same validated process. No technology transfer needed.
Redundancy & Continuity
With a total plant capacity exceeding 100,000,000 capsules monthly, if one line undergoes maintenance, the others keep your production on schedule. Business continuity is built-in.
The Softgel Paradigm
Superior API Delivery Format
Softgel capsules encapsulate liquid, semi-solid, or oil-based Active Pharmaceutical Ingredients (APIs) within a hermetically sealed gelatin or plant-based biopolymer shell — delivering measurable physiological and commercial advantages over standard delivery formats.
Enhanced Bioavailability
Lipid matrices drastically accelerate absorption in the gastrointestinal tract, especially for poorly soluble substances such as omega fatty acids, fat-soluble vitamins (A, D3, E, K2), herbal oil extracts, and Coenzyme Q10.
Total Protection & Masking
The hermetic seal perfectly masks unpleasant tastes and odours while shielding sensitive compounds from oxidation, moisture, and UV radiation — extending shelf life and preserving therapeutic potency.
Technology
Rotary Die Encapsulation
Our three industrial lines utilize the advanced rotary die method — the gold standard in pharmaceutical softgel manufacturing. Two continuous gelatin ribbons are formed, filled with a precisely dosed payload (±2% variance), and hermetically sealed in a single uninterrupted cycle.
Every capsule is monitored by PLC systems and proprietary AI algorithms tracking ribbon thickness, fill weight, temperature, and seal integrity in real time. We maintain a Process Performance Qualification (PPQ) with Cpk greater than 1.33 for all critical parameters.
The result: absolute therapeutic consistency. In 17 years of operation, across more than 350 global implementations, we have recorded zero QA product complaints.
5-Step Production Process
Rotary Die: From Mass to Market
Olympia Biosciences™ utilises the industry-leading Rotary Die technology — originally invented by Robert Pauli Scherer in 1931 — to continuously form, fill, and seal capsules in a single automated cycle across five critical engineering stages.
01
Mass Preparation
Pharmaceutical-grade gelatin (Type A or B) or vegan biopolymers are combined with plasticisers (glycerol, sorbitol) and water in a vacuum-heated mixer to create a homogeneous, bubble-free elastic base.
02
Encapsulation
Two heated ribbons of base mass are fed into the machine. A precise liquid or suspension fill is injected between them under pressure, shaping the three-dimensional capsule while it is instantaneously welded and cut.
03
Drying & Stabilisation
Moist capsules undergo preliminary drying in tumble dryers, followed by curing on perforated trays in climatic chambers (20–25°C, 20–30% humidity) until reaching an optimal final moisture content of 6–8%.
04
Finishing
Capsules are polished (mechanically or via air), sorted using automated inspection systems to eliminate defects, and prepared for downstream packaging operations.
05
Custom Packaging
Options include PVC/Alu or Alu/Alu blisters, glass or PET jars, and doypacks — complete with custom colouring and precision laser printing to prevent counterfeiting.
Supply Chain & R&D
Beyond Manufacturing.
We do not just encapsulate your formula. We secure your entire supply chain and inject world-class biotechnology into your product matrix.
Direct Sourcing (EKLAVYA BIOTECH)
Most CDMOs rely on European brokers for raw materials, adding margins and losing traceability. Through our subsidiary EKLAVYA BIOTECH in India, we control the quality and availability of critical APIs and extracts directly at the source.
Cambridge Micellar Softgel Technology
We were selected by the University of Cambridge and Adiuvo S.A. (GPW-listed) to scale their exclusive micellar technology from laboratory to industrial softgel production. This was not a generic licensing deal. Cambridge needed a facility capable of encapsulating nano-micellar matrices in softgels at scale without degrading the active compounds. They chose us.
We now apply this same bioavailability engineering to every custom softgel formulation we develop. The result is dramatically higher absorption rates compared to standard oil-fill softgels.
Industry 4.0 & R&D
Next-Generation Formulation Technologies
Olympia Biosciences™ integrates Industry 4.0 principles across production, utilising AI algorithms and Big Data to optimise line pressure, temperature, and humidity in real time. Our Evidence-Based Medicine R&D capabilities establish a decisive competitive edge.
Liposomal Technology & Nano-Micellisation
Encases APIs in protective lipid layers or micro-particles, radically increasing cellular-level absorption and enabling premium, high-margin product positioning with clinically verifiable bioavailability advantages.
Advanced Emulsification (SEDDS)
Self-microemulsifying drug delivery systems ensure stable fat-water formulas with high gastric tolerance — ideal for challenging APIs that resist standard oil-fill approaches.
Supercritical CO₂ Extraction
Yields absolutely pure, heavy-metal-free botanical oils without toxic solvents, facilitating stringent Clean Label certifications and the highest-purity botanical extracts available.
Vegan Biopolymers
100% plant-based shells (agar or carrageenan) that eliminate cross-linking risks and meet global ESG sustainability demands, opening premium vegan and religious-compliant market segments.
Cold Process Mixing & Microencapsulation
Protects thermolabile APIs and enzymes from heat degradation and ensures smart, slow-release of substances — critical for probiotic and enzyme-based premium formulations.
Capabilities
What We Encapsulate
From classic fish oils to advanced lipid-based drug delivery systems. Every formula designed from scratch by our R&D team — you own 100% of the IP.
Oils & Lipids
- Omega-3 (EPA/DHA) — fish & algal
- Vitamin D3 in MCT oil
- Vitamin E (tocopherols)
- Evening primrose / borage oil
- Coenzyme Q10 (ubiquinol)
- Krill oil concentrates
Specialty & Pharma
- CBD / cannabinoid formulations
- Curcumin (lipid-solubilized)
- Astaxanthin suspensions
- Lutein / zeaxanthin blends
- Iron bisglycinate in oil
- FSMP medical food matrices
Cosmetic & Twist-Off
- Retinol serums (single-dose)
- Vitamin C concentrates
- Hyaluronic acid ampoules
- Hair & nail oil capsules
- Collagen peptide blends
- Custom cosmeceutical APIs
Personalization
Your Capsule. Your Brand.
Every parameter is customizable. Shape, size, color, opacity, printing, fill composition — engineered to match your brand identity and therapeutic intent.
Shapes & Sizes
Oval, oblong, round, and custom geometries. From mini 3-minim to large 40-minim capsules. Pediatric-friendly sizes available.
Colors & Opacity
Full Pantone color matching. Transparent, translucent, or opaque shells. Iron oxide and titanium dioxide opacifiers for light-sensitive actives.
Printing & Marking
Ink printing or laser engraving. Brand logos, dosage info, or batch codes directly on the capsule shell. Pharma-grade inks only.
Packaging Options
Blisters (PVC/PVDC/Alu), HDPE bottles, glass jars, sachets, or bulk drums. Automatic blistering lines on-site. Full private label service.
Advanced Delivery Systems Guide
Softgel Encapsulation
Olympia Biosciences™ CDMO, operating under global ISO 22000 and GMP standards since 2009, specializes in premium softgel encapsulation and nano-micellization. Utilizing pharmaceutical-grade rotary die methods, active matrix fillings are precisely sealed, ensuring absolute bioavailability that standard powders cannot achieve.
Hard Capsule Systems
Formed from two precision-engineered cylindrical shells joined after filling with active substances. Ideal for dry powders, granules, pellets, and multi-component fill matrices where bioavailability engineering demands a controlled-release architecture.
Custom Production
Custom Production allows brands to launch clinical-grade supplements without investing in their own manufacturing infrastructure. From 300,000 capsule minimum orders to 100M+ monthly volumes at the same ISO-certified facility and validated process.
Quality Assurance
Pharma-Grade Quality. Zero Complaints Since 2009.
Every softgel batch undergoes multi-point quality control — from raw material testing through in-process monitoring to final release analytics.
Zero Complaints
Since 2009. Not a single QA product complaint across 350+ global implementations. That is statistical perfection.
ISO Certifications
ISO 9001, 22000, 22716, 27001, GMP/HACCP (Codex Alimentarius), certified by POLCARGO GROUP Ltd.
AI-Verified Safety
Every formula is designed by our R&D scientists, then additionally screened by our proprietary AI for ingredient interactions and toxicological risks.
Monthly Capacity
Years in Production
Export Volume
Product Complaints
Strategic Cooperation Models
Choose Your Path to Market
Olympia Biosciences™ tailors its collaboration framework based on partner scale and strategic objectives. Three distinct pathways ensure optimal OPEX, IP protection, and time-to-market for every client profile.
For Production Transfers 1M+ Units
VIP Fast-Track — Mass Transfer
Designed for corporate projects relocating established production of over 1,000,000 units. With a ready Master Batch Record (MBR/BOM), clients bypass standard R&D queues and development fees — the fastest path to production continuity.
For Clinics & Premium Brands
Medical Innovation R&D
Exclusively for clinics and premium brands demanding clinical efficacy. Olympia Biosciences™ designs custom matrices using patented raw materials verified by global scientific literature (DOI), delivering a complete Medical Dossier and full IP Buy-Out for the client.
For New Custom Formulations
Start-ups & Scaling Brands
Selected brands gain access to our full ROlympia Biosciences™'s full R&D pipelineD pipeline through a structured Discovery engagement — a protected CAPEX investment fully capitalised against the first mass production order. Every formula is engineered to GIS/EFSA standards from day one, securing your market entry, regulatory position, and IP before a single capsule ships. Selective partnerships begin at 300,000 capsules MOQ.
Time-to-Market
Complex, custom OEM formulations: 3–6 months
White Label from existing validated bases: a few weeks
Ready to manufacture softgels
that set the standard?
Apply for a technological audit. Our R&D team will evaluate your formula, recommend the optimal capsule format, and provide a detailed production timeline.
Apply for R&D AuditFrequently Asked Questions
How many softgel encapsulation lines does Olympia Biosciences™ operate?
What types of softgel capsules can you manufacture?
What is the minimum order quantity for softgel manufacturing?
What gelatin and shell materials do you use for softgel manufacturing?
Can Olympia Biosciences™ manufacture enteric-coated softgels?
What is the lead time for softgel contract manufacturing at Olympia Biosciences™?
Strictly B2B / Educational R&D Disclaimer
The pharmacokinetic data, clinical references, and scientific literature referenced on this page are provided strictly for B2B formulation, educational, and R&D purposes for medical professionals, pharmacologists, and brand developers. Olympia Biosciences™ operates solely as a Contract Development and Manufacturing Organization (CDMO) and does not manufacture, market, or sell consumer end-products.
Global Regulatory & No Health Claims. Nothing on this page constitutes a health claim, medical claim, or disease-risk-reduction claim within the meaning of EU Regulation (EC) No 1924/2006, the U.S. Dietary Supplement Health and Education Act (DSHEA), or other global regulatory frameworks. These statements and raw data have not been evaluated by the Food and Drug Administration (FDA), European Food Safety Authority (EFSA), or Therapeutic Goods Administration (TGA). The raw active pharmaceutical ingredients (APIs) and formulations discussed are not intended to diagnose, treat, cure, or prevent any disease.
Client Responsibility. The B2B client who commissions a formulation from Olympia Biosciences™ bears full and sole responsibility for all regulatory compliance, health claim authorization (including EFSA Article 13/14 claim dossiers and U.S. FDA notifications), labeling, and marketing of their finished product in their target market(s). Olympia Biosciences™ provides manufacturing, formulation, and analytical services only.