In softgel manufacturing, cleanliness isn’t just about compliance — it directly impacts product quality, batch integrity, and operational efficiency. But cleaning gelatin buildup, plasticizers, oils, and pigments from stainless steel processing equipment is no easy task. Traditional wipes and detergents often fall short, especially when residues become heat-cured or tacky.
That’s where Foamtec’s Sahara+ Cleaning System steps in — a validated, multi-stage cleaning process engineered to break down stubborn residues and restore critical equipment surfaces to GMP standards.
The Cleaning Challenge in Softgel Facilities
From gelatin melting tanks and fill ports to encapsulation dies, transfer tubing, and polishing drums, softgel manufacturing equipment is exposed to:
- Heat-dried gelatin films
- Sticky plasticizers like glycerin and sorbitol
- Oily coatings from MCT or mineral oils
- API suspensions and pigmented residues
These materials cling to surfaces, resist simple wipe-downs, and leave behind streaks or particles that can compromise batch quality or trigger FM investigations.
Foamtec’s Sahara+ Cleaning System: Three Products, One Proven Process
Foamtec’s Sahara+ system offers a sequential, operator-friendly cleaning method that uses three high-performance tools:
Step 1: Break the Bond with Sahara Scrubbing Foam
Product: Sahara Foam scrubbing wipers or Sahara Foam Heads (for mops or tools)
Purpose: Mechanically disrupt and loosen dried-on residues
- Made from high-density, open-cell polyurethane foam
- Designed with a textured surface that lifts gelatin films, oils, and dried residue without scratching polished steel or anodized surfaces
- Won’t scratch plastics, stainless or electropolished steel
- Can be used wet with DI water, IPA, or approved detergents — no need for scouring pads or brushes
- Available in ergonomic formats: hand pads, mop heads, swabs
Use It On: Gelatin tanks, encapsulation dies, hopper ports, polishing trays, and conveyor belts
Step 2: High-Volume Oil Absorption with UltraSORB Foam Wipers
Product: UltraSORB sponge Wipers
Purpose: Rapidly absorb large volumes of oil, plasticizers, and loosened residues following Sahara scrubbing
- Made from ultra-absorbent reticulated polyurethane foam
- Engineered to wick up heavy oil loads from gelatin melting tanks, polishing drums, and encapsulation tooling
- Ideal for high-throughput oil removal without dripping or smearing
- ISO 5 processed and validated for use in GMP environments
Use It On: Gelatin tanks, oil-lubricated polishing drums, and other equipment where excess mineral oil or MCT residue accumulates
Step 3: Final Cleaning and Inspection-Ready Polishing with MiraWIPE
Product: MiraWIPE Cleanroom Microfiber Wipers
Purpose: Leave stainless and electropolished steel surfaces streak-free, particle-free, and ready for QA inspection or swab validation
- Constructed from split microfiber yarn with exceptional surface contact
- Captures and traps particles at the submicron level
- Provides a streak-free, mirror-like finish on critical contact surfaces
- It is ideal as the final wipe before reassembly or inspection
Use It On: Fill tanks, encapsulation equipment, spray nozzles, transfer lines, and other validated contact surfaces
The Engineering Advantage: A Validated, Operator-Friendly Solution
- Eliminates the need for scouring pads, brushes, or fiber-shedding towels
- Reduces rework and cleaning time, especially in hard-to-reach areas
- Compatible with cleaning validation protocols — supported by TOC, particulate, and residue testing data
- Enhances compliance with Annex 1, FDA, and ISO 14644-1 standards
- Reduces FM contamination risk from traditional cloths or reused tools
Results That Matter
With the Sahara+ Cleaning System, softgel engineers can expect:
✔ Fewer visual defects caused by residual oils
✔ Faster removal of heavy oil and residue loads
✔ Mirror finishes that pass pre-op inspections with confidence
✔ Shorter cleaning time per batch
✔ Lower FM risk and reduced likelihood of line shutdowns
Conclusion: Cleaning Softgel Equipment Doesn’t Have to Be a Struggle
Foamtec’s Sahara+ Cleaning Process gives softgel manufacturers a GMP-validated, easy-to-train solution for removing stubborn residues without abrasive pads, cross-contamination risks, or unverified cleaning tools. It’s a wise investment in uptime, product quality, and peace of mind.
Want to see the Sahara+ process in action?
Contact Foamtec to request a demo kit or schedule a line-side cleaning evaluation.