System for recovery of waste gel-mass from softgel manufacturing process

1. A system for recovering gel-mass from a gel-mass-containing waste material generated by an encapsulation process, the system comprising:

(a) mangle rolls to retrieve the gel-mass-containing waste material from said encapsulation process;

(b) a heated accumulator for receiving and melting the gel-mass-containing waste material recovered in step (a) under conditions that provide an oil phase and a non-oil phase of said molten waste material;

(c) a displacement liquid system for providing an oil-phase miscible displacement liquid to the heated accumulator to facilitate melting and separation of air and the oil phase and non-oil phase; and

(d) at least one pump for transporting the non-oil phase from the heated accumulator to a location to be combined with fresh encapsulating material to provide a combined encapsulating material for use in encapsulating additional product from a same lot of the product encapsulated in the encapsulation process; and

(e) a controller for controlling the system for recovering the gel-mass.

2. The system of claim 1 , further comprising a mixer for mixing the gel mass to provide a mixed gel mass.

3. The system of claim 1 , wherein the mangle rolls are configured as sanitary mangle rolls.

4. The system of claim 2 , further comprising at least one moisture sensor to detect a water content of the mixed gel-mass.

5. The system of claim 4 , further comprising a water dosing system configured for adding water to the mixed gel-mass.

6. The system of claim 1 , wherein the heated accumulator is configured to receive the gel-mass-containing waste material at a first end of said accumulator and separate the molten waste material into the oil phase and non-oil phase at a second end of said accumulator.

7. The system of claim 1 , further comprising at least one sensor to detect separation levels of the oil phase and the non-oil phase in the heated accumulator and wherein the at least one sensor is selected from a capacitance sensor, a pressure sensor, buoyancy sensor, differential thermal sensor, and a conductivity sensor.

8. The system of claim 1 , wherein the mangle rolls comprise a pair of knurled cylinders.

9. The system of claim 1 , wherein the mangle rolls employ sealed bearings.

10. The system of claim 1 , wherein the system includes only a single pair of mangle rolls.

11. The system of claim 1 , wherein the system includes more than one pair of mangle rolls.

12. The system of claim 1 , wherein the mangle rolls include meshing curvilinear and elongated teeth configured to engage one another to grasp the gel mass- containing waste material therebetween.

13. The system of claim 1 , further comprising:

a gel supply for supplying the fresh encapsulating material;

a second mixer at the location for combining the mixed gel-mass with the fresh encapsulating material; and

a pump for pumping the fresh encapsulating material from the gel supply to the second mixer.

14. The system of claim 1 , wherein the heated accumulator is configured to melt the gel-mass containing waste material at a temperature in a range of from about 45° C. to about 90° C. and at a reduced pressure lower than one atmosphere.

15. The system of claim 1 , further comprising one of a fractional distillation apparatus, a short path distillation apparatus and a reverse osmosis apparatus for recovering lubricating oil from the oil phase.

16. The system of claim 1 , further comprising a filter for filtering the non-oil phase.

17. They system of claim 16 , wherein the filter is configured to perform a filtration step selected from pressure filtration, hot filtration and diafiltration.

18. The system of claim 1 , configured to feed the recovered gel-mass to an encapsulation step in a manner which ensures that the recovered gel-mass is present in only a portion of a capsule shell formed in said encapsulation step.