Many supplement manufacturers assume that a "pre-gel" setting step-where the capsule or gummy is partially cooled or dried before demolding-is always necessary to prevent distortion or sticking. This assumption often stems from poor release performance with standard mold release agents. However, if you switch to a properly formulated mold release agent designed for your specific material (e.g., a food-grade lecithin-based spray or a silicone-based lubricant) or use a non-stick surface (such as PTFE-coated or silicone molds), the pre-gel step may become unnecessary. In fact, with these alternatives, demolding can often proceed immediately after gelation or cooling, saving production time and reducing risk of damage to the product.
The key variables are the release agent’s coating uniformity and the surface’s slip properties. A high-quality release agent eliminates mechanical adhesion, while a non-stick surface reduces the frictional force during demolding. This means the product can be demolded as soon as it reaches sufficient rigidity-without needing a lengthy "pre-gel" stage. For example, in gummy manufacturing, if you use a non-stick silicone mold, you can demold at room temperature as soon as the gummy sets, whereas with an inadequate release agent, premature demolding might cause tearing or sticking. Similarly, in capsule production, a properly applied release agent can allow demolding immediately after the capsule shell cools, skipping the typical 10-15 minute stabilization step.
Here’s a quick comparison to illustrate the potential change:
- With standard release agent (inadequate): Pre-gel step (5-20 minutes) required to let the product shrink slightly and harden, reducing sticking and surface damage.
- With optimized mold release agent: Minimal or no pre-gel step-product can be demolded once firm, often within seconds of reaching set temperature.
- With non-stick surface (e.g., PTFE, silicone): No pre-gel needed-product releases as soon as it holds its shape, even if still slightly warm.
At KorNutra, we focus on providing precise release solutions for your production needs. Always test your specific formulation and mold release combination to confirm the optimal timing, as factors like ingredient viscosity and mold geometry can still influence results. But in many cases, the assumption that pre-gel is mandatory is incorrect-especially when you upgrade your release agent or mold surface. This can streamline your process, reduce cycle times, and improve yield.