Frontline Food Consultants & Engineers is dedicated to helping you create the best quality fish oil and omega-3 supplements that cater to the increasing demand for health-focused products. Understanding the important role these supplements play in supporting heart and brain health. We work with you at every stage of the development process. We assist our clients in sourcing the finest fish oils to craft formulations that deliver the maximum benefits of omega-3 fatty acids. Our dedicated team of industry experts ensures your products are both effective and appealing.

FFCE focuses on the key aspects of production, including new product development to design supplements that stand out in the market. The technological support to incorporate advanced processes like molecular distillation is essential for ensuring the purity and potency of your products. Our Process Improvement services help streamline production, making it more efficient and cost-effective. Our regulatory compliance & documentation for Fish oils and omega-3 supplements services ensure that your supplements meet all required standards. 

We offer complete end-to-end Turnkey Solutions for Fish Oils and Omega-3 Supplements, in which every aspect of the product is covered by FFCE, we will take care of everything, right from the ideation to plant/factory setup, layout, planning machinery setup construction,  compliances, audits, lab setups, and commercialization. Or, in case you don’t wish to set up a manufacturing unit up front, we also offer Third-Party Manufacturing Collaborations to help scale your production. 

What are Fish Oils and Omega-3 Supplements?

Fish oils and omega-3 supplements are health products derived primarily from the tissues of fatty fish such as salmon, mackerel, and sardines. These supplements are rich in essential omega-3 fatty acids, including eicosapentaenoic acid (EPA) and docosahexaenoic acid (DHA), which are known for their significant benefits to heart and brain health. Setting up a manufacturing unit for producing these supplements involves more than just extracting the oils; it requires a deep understanding of both the raw materials and the processes that ensure the highest quality end product.

To produce fish oils and omega-3 supplements, you’ll need to invest in advanced machinery such as molecular distillation units, which are crucial for removing impurities and achieving the desired concentration of omega-3s. Encapsulation equipment is also essential for creating the final product in various forms, such as soft gel capsules or liquid formulations, depending on market demand. Additionally, maintaining strict control over the sourcing of raw materials and implementing strict quality assurance processes are critical to ensuring the purity, potency, and stability of the supplements.

Types of Omega-3 Supplements

Omega-3 supplements are available in various forms, each offering unique benefits:

  1. Fish Oil Supplements
    • Profile: Contains EPA and DHA, the most bioavailable forms of omega-3s.
    • Sources: Derived from fatty fish such as anchovies, mackerel, and sardines.
    • Forms: Available in soft gel capsules, liquid oils, and emulsions.
  2. Krill Oil Supplements
    • Profile: Contains EPA and DHA, along with phospholipids and antioxidants like astaxanthin.
    • Sources: Extracted from Antarctic krill, a small crustacean.
    • Benefits: Easier to absorb due to phospholipid content; also provides antioxidant benefits.
  3. Cod Liver Oil Supplements
    • Profile: Provides EPA, DHA, and vitamins A and D.
    • Sources: Extracted from the liver of codfish.
    • Benefits: In addition to omega-3s, it offers fat-soluble vitamins that support overall health.
  4. Algal Oil Supplements
    • Profile: Contains DHA and, in some cases, EPA; suitable for vegetarians and vegans.
    • Sources: Derived from algae, a sustainable and plant-based source.
    • Benefits: Ideal for those who avoid fish products; sustainable and eco-friendly.
  5. Flaxseed Oil Supplements
    • Profile: Rich in ALA, a plant-based omega-3 fatty acid.
    • Sources: Extracted from flaxseeds.
    • Benefits: Suitable for vegetarians and vegans; supports cardiovascular health.

The Production Process of Fish Oils and Omega-3 Supplements

The production of fish oils and omega-3 supplements involves several critical steps to ensure purity, potency, and safety:

  1. Sourcing and Extraction
    • Objective: Obtain high-quality raw materials rich in omega-3 fatty acids.
    • Process: Sourcing fish or other marine organisms from sustainable and certified fisheries. The oil is extracted using methods such as steam distillation or cold pressing to preserve the integrity of the fatty acids.
  2. Purification and Refinement
    • Objective: Remove impurities and contaminants.
    • Process: The extracted oil undergoes purification processes, such as molecular distillation, to remove contaminants like heavy metals, PCBs, and other environmental toxins. This step ensures that the final product is safe and free from impurities.
  3. Concentration and Standardization
    • Objective: Enhance the concentration of EPA and DHA.
    • Process: The oil may be further refined to increase the concentration of omega-3 fatty acids, particularly EPA and DHA. This process involves techniques such as ethylation and winterization, resulting in a more potent supplement.
  4. Encapsulation and Formulation
    • Objective: Create consumer-friendly product formats.
    • Process: The purified and concentrated oil is encapsulated in soft gel capsules or formulated into liquid oils and emulsions. Emulsification can improve the absorption and bioavailability of the omega-3s.
  5. Quality Control and Testing
    • Objective: Ensure the safety, potency, and efficacy of the supplements.
    • Process: Comprehensive testing for purity, potency, and stability, including checks for omega-3 content, oxidation levels, and absence of contaminants. Sensory evaluations are also conducted to ensure product quality.

Engineering of Packaging Materials for Omega-3 Supplements

Packaging plays a crucial role in preserving the quality and stability of fish oils and omega-3 supplements. The choice of packaging materials must protect the product from oxidation, UV light, and environmental factors.

  1. Softgel Capsules
    • Objective: Provide a convenient and protective format for omega-3 oils.
    • Materials: Typically made from gelatin or vegetarian alternatives such as carrageenan or modified starch.
    • Benefits: Softgels protect the oil from oxidation and are easy to swallow. They can also mask the taste and odor of fish oil.
  2. Bottles and Containers
    • Objective: Store liquid oils and emulsions securely.
    • Materials: Amber or dark-colored glass bottles are often used to protect the oils from light exposure, which can degrade the omega-3 content. High-density polyethylene (HDPE) or polyethylene terephthalate (PET) bottles are also common.
    • Benefits: Glass bottles provide a strong barrier against oxygen and moisture, preserving the oil’s quality. PET bottles are lightweight, shatter-resistant, and provide good barrier properties.
  3. Blister Packs
    • Objective: Provide individual servings and enhance portability.
    • Materials: Blister packs are made from materials like aluminum or plastic, offering excellent protection against moisture and oxygen.
    • Benefits: Blister packs protect each capsule individually, extending shelf life and providing convenience for on-the-go consumption.
  4. Nitrogen Flushing and Sealing
    • Objective: Prevent oxidation and maintain freshness.
    • Process: Nitrogen flushing is used to displace oxygen in the packaging, reducing the risk of oxidation and rancidity. Sealing methods, such as induction sealing or tamper-evident closures, ensure product integrity.