Disclosed herein are a manufacturing process for encapsulating at least one solid inclusion into a softgel capsule. Also disclosed herein is a system for secondary encapsulation of solid inclusions using the rotary die process and system. Also disclosed herein are dosage forms having at least one solid inclusion encapsulated therein.

A method of forming dual layer water soluble packets includes drawing a base film into a cavity of a mold, drawing air through openings in the base film, metering an amount of a first product of a first color onto the base film in the cavity, metering an amount of a second product of a second color onto the amount of the first product, and, sealing a lid film to the base film.

Systems and methods to form openings in water soluble packets are described. The system includes a packet forming assembly to form water soluble packets, and a laser to form one or more openings in the water soluble packets. The method includes forming openings in the water soluble packets with a laser. The openings permit air to escape from the packets. By allowing air to escape, the water soluble packets have improved packaging characteristics. The water soluble packets are packed more tightly with a product.

A method of forming dual layer water soluble packets includes drawing a base film into a cavity of a mold, drawing air through openings in the base film, metering an amount of a first product of a first color onto the base film in the cavity, metering an amount of a second product of a second color onto the amount of the first product, and, sealing a lid film to the base film.

A flexible package having first, second, and third flexible material layers, with the second flexible material layer being disposed between the first and third flexible material layers; a product receiving chamber having a product receiving chamber outer circumference defined by the first flexible material layer; a plurality of spaced first seals disposed around a package circumference, the first seals sealing the first, second and third flexible material layers together; a plurality of spaced second seals disposed around the product receiving chamber outer circumference, the second seals sealing the second and third flexible material layers together; a plurality of inner expansion chambers, each one of the plurality of chambers being defined between adjacent ones of the first seals; and a plurality of outer expansion chambers, each one of the plurality of chambers being defined between a second seal and an immediately adjacent first seal.

Apparatus and method for separating product containing pouches from a travelling web of adhered films carried on a film support surface includes a rotary blade drum assembly having blade configurations with blade portions arranged to form the entire perimeter edge of the flange of the pouch which rotate in synchronous registration with grooves in the film support surface. In one form, at least one blade portion and associated groove portion are non-linear and other than longitudinal or transverse to the film support surface of the forming drum or travelling web of films. The blade portions may be heated and the rotary blade drum assembly may include insulating guides for the pouches.

A shipping package having a flexible inner sheet having a first surface and a second surface. The package has an article reservoir for accepting an article to be shipped and one or more expansion chambers. The expansion chambers can be inflated or otherwise expanded to provide structure to the package and to protect the article in the article reservoir.

Apparatus for forming product containing pouches from a travelling web of adhered films includes a film support surface, including a plurality of mold configurations, and a film retention chamber in the film support surface preceding and trailing each of the mold configurations. A vacuum system applies vacuum to the mold configurations and film retention chambers to form product containing pockets and to secure the film in the film retention chambers. Separation blades in synchronous register with the mold configurations separate the pouches from the travelling web. In one form the film support surface comprises a rotary forming drum and a rotary blade drum includes the separation blades.

The present invention related to an apparatus and method for the manufacturing of beverage capsules. The apparatus can preheat the material used to form the beverage material during the manufacturing process. The material and apparatus are particularly suitable for use in producing single serve beverage capsules from biodegradable materials.

A packaging system (1) for producing pouches having multiple compartments and made from a first water-soluble foil (5) and a second water-soluble foil (6), which packaging system (1) comprises a mould conveyor (7) to move multiple moulds (8) in a conveying direction (9) along an endless trajectory, a suction device (14) configured to suck the first foil into the first suction chambers (11) and the second suction chambers (12), a first foil supplying device (16), a powder filling device (25) configured to fill the first compartment with a powder in an accurate manner, a further filling device (28) configured to fill the second compartment with a further powder or a liquid, and a second foil supplying device (17).