detailed embodiments of devices , systems , and methods are disclosed herein , however , it is to be understood that the disclosed embodiments are merely exemplary of the devices , systems , and methods , which may be embodied in various forms . therefore , specific functional details disclosed herein are not to be interpreted as limiting , but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure . in an illustrative embodiment , a soft gel capsule and a method of making the soft gel capsule is disclosed herein . in general , the soft gel includes an outer shell and a filling . in an illustrative embodiment , the outer shell is sealed at a selected temperature range forming a seam in which the gelatin is cross - linked across the seam . for example , the outer shell may be sealed at a temperature of about 10 ° c . to about 60 ° c ., more preferably about 12 ° c . to about 30 ° c ., and more preferably about 17 ° c . to about 23 ° c . ( about 62 ° f . to about 73 ° f .). in accordance with these temperature range ( s ), the soft gel shell may be sealed and the cross - linked gelatin seam may be formed using light energy ( i . e . photo sealing and / or photocrosslinking ) for example , light , such as but not limited to , ultraviolet light and other types of light in the light spectrum may be used to create the cross - linked gelatin seam . the outer shell may be composed of at least one gelatin , for example , including , but not limited to a gelatin derived from pigskin , a gelatin derived from bovine bone , a gelatin derived from fish gelatin , other animal - derived gelatin , a chemically modified gelatin , a mixture of gelatin , gelatin elastin mixtures , gelatin ground substance mixtures , partially or completely polymerized gelatins and gelatin mixes , polymers of glycine , proline and any third aminoacid as synthetic gelatin and other gelatins , gelatin hydrolysates and gelatin fragments of the type and combinations thereof . in an illustrative embodiment , the outer shell may include gelatin in an amount of about 10 % to about 99 %, more particularly from about 75 % to about 95 %. the outer shell may also include one or more additional components , for example , including , but not limited to a coloring agent , a flavoring agent , a plasticizer , a modifier , water , an antioxidant , an anti - tack agents , a softening agent , a starch , an opacifying agent , a water binding or releasing agent , a fatty acid or wax , a cation , an anion , glycerol , glycerin , a synthetic analogue with the same functional properties and other components of the type and combinations thereof . in an illustrative embodiment , the outer shell may include a gelatin mass at approximately 65 % w / v , glycerol at approximately 15 % w / v , sorbitol or sorbitan or equivalents at approximately 14 % w / v , purified water at approximately 5 % and caramel at approximately 1 %. in one illustrative embodiment , one or more opacifying agents such as , but not limited to , caramel , titanium dioxide , iron oxide , and plant extracts may be optionally present in an amount of about 0 . 1 % to about 10 %. in a further illustrative embodiment , the optional opacifying agent is present in about 0 . 5 %- 5 %. in another illustrative embodiment , the soft gel may be composed of gelatin and caramel . the gelatin may be kosher certified gelatin and be present in an amount of about 400 mg ( 150 bloom , 99 %). the caramel may include , but is not limited , to type 1 , type 2 , type 3 or type 4 from sethness caramel color , lincolnwood , ill ., and be present in an amount of about 9 mg to about 36 mg ( opacity index / color , ap100 ). the caramel may be any color and any type as known in the art . in a further illustrative embodiment , the soft gel may be composed of gelatin and caramel and filled with an elemental magnesium composition as shown in table 1 below : the flow rate , temperature , humidity , and pressure are controlled to achieve a consistent flow of the fill composition or emulsion such that from about 1 to about 1000 soft gels are produced each minute of operation at consistent size , shape and with a barely visible seam that allows gelatin molecules to cross link between the soft gel layers to produce a single unit from an upper and a lower sheet with a predetermined weight of material to fill the interior . a method 100 of making the soft gel according to an illustrative embodiment is described with reference to fig1 . as illustrated in fig1 , sheets of gelatin are made , illustrated as block 102 , and aligned with one another , illustrated as block 104 . the sheets of gelatin may be composed as described herein . a consistent and defined amount of fill material is disposed between two leaves ( an upper and a lower sheet ) of gelatin , illustrated as block 106 , and the edges of the two leaves are heat or photo sealed forming a seam in which the gelatin is cross - linked across the seam , illustrated as block 108 . the consistent and defined amount of fill material may include about 1200 mg of fill to about 475 mg of gel mass shell for a total weight of about 1675 mg per soft gel . soft gels are sized as they are produced . approximately 95 percent of the soft gels produced should be at the pre - determined size such as a 20 oblong soft gel . soft gels are then cured or dried according to the art , illustrated as block 110 , such as in a drying tunnel and further dried with lint - free cloths . in a further illustrative embodiment , the filling of the soft gel capsule may be a magnesium complex . the magnesium complex may include but is not limited to a magnesium salt , a quaternary amine or phosphatide and a di - carboxylic acid or tri - carboxylic acid . the magnesium salt may be any known magnesium salt or a combination of known magnesium salts . exemplary magnesium salts include but are not limited to magnesium oxide , magnesium glycinate , magnesium ascorbate , magnesium chloride , magnesium sulfate , magnesium orotate , magnesium citrate , magnesium fumarate , magnesium malate , magnesium succinate , magnesium tartrate and magnesium carbonate and anhydrous or structural homologue forms of each of the above . the magnesium salt may be an anhydrous magnesium salt that is micronized to form a power having heterogeneous particle sizes . the micronization may include milling the anhydrous magnesium salt using a pin mill or other type of milling technique . the particle sizes may be selected to achieve a proper viscous flow rate , proper emulsion , and achieve an effective fill of a smaller volume when the magnesium salt is incorporated into the fill composition . for example , the micronized magnesium salt may have a mean particle size distribution ( d50 ) of about 15 microns to about 35 microns , and a peak particle size of about 80 microns to about 180 microns . without being bound to any particular theory it is believed that the micronization of the magnesium salt increases the surface area of the magnesium and therefore the bioavailability of the magnesium thereby resulting in an increased uptake of magnesium . the quaternary amine or phosphatide may include any quaternary amine , phosphatide or a combination of quaternary amines and phosphatides . an exemplary quaternary amine is choline . the di - carboxylic acid or tri - carboxylic acid may include any di - carboxylic acid , tri - carboxylic acid or combination of di - carboxylic acids and tri - carboxylic acids . an exemplary tri - carboxylic acid is citrate . the magnesium complex may also include one or more additional components , for example , including , but not limited to water , de - ionized water , glycerol , one or more medium chain triglycerides ( mcts ), one or more oils , one or more diluents , one or more lubricants , one or more stearates , one or more disintegrants , one or more fillers , one or more stabilizers , one or more surfactants , and other components of the type and combinations thereof . suitable diluents include but are not limited to dicalcium phosphate , calcium sulfate , lactose , cellulose , kaolin , mannitol , sodium chloride , dry starch , and powdered sugar . lubricants are used to facilitate tablet manufacture ; examples of suitable lubricants include but are not limited to magnesium stearate , calcium stearate , and stearic acid . stearates , if present , preferably represent at no more than approximately 2 wt . % of the drug - containing core . disintegrants are used to facilitate disintegration of the tablet , and are generally starches , clays , celluloses , algins , gums , or cross - linked polymers . fillers include but are not limited to materials such as silicon dioxide , titanium dioxide , alumina , talc , kaolin , powdered cellulose , and microcrystalline cellulose , as well as soluble materials such as mannitol , urea , sucrose , lactose , dextrose , sodium chloride , and sorbitol . stabilizers that are now within the pharmaceutical art are used to inhibit or retard drug decomposition reactions that include but are not limited to oxidative reactions . surfactants may be anionic , cationic , amphoteric , or nonionic surface active agents . in one embodiment , the filling includes pc - 35 ( 35 % phosphatidylcholine ), medium - chain triglycerides ( mcts ), magnesium citrate , and optionally , water . the pc - 35 may be present in an amount of about 380 mg based on an average mw of phosphatides of about 760 . the mcts may be used as a carrier and be present in an amount of about 225 mg . the magnesium citrate may be present in an amount of about 690 mg to provide about 110 mg elemental magnesium based on about 16 % elemental magnesium in tri - magnesium citrate , anhydrous api material from jost chemical co ., st . louis , mo . the water may be deionized water with nitrogen purged and be added as needed . in this embodiment , the total fill weight of the filling within the soft gel may be about 1300 mg . however , it will be appreciated by those skilled in the art that the total fill weight may be modified based on the size and shape of the soft gel . a method 200 of making a soft gel with a magnesium complex filling according to an illustrative embodiment is described with reference to fig2 . as illustrated in fig2 , an anhydrous magnesium powder , such as tri - magnesium citrate , anhydrous , ultra - fine powder from jost chemical co ., st . louis , mo ., is obtained , illustrated as block 202 . the magnesium powder is micronized into a powder having a heterogeneous particle size , illustrated as block 204 . the micronized magnesium power is suspended in an oil and phosphatide emulsion , illustrated as block 206 . the emulsion is disposed between two leaves ( an upper and a lower sheet ) of gelatin , illustrated as block 208 , and the two leaves are heat or photo sealed forming a seam in which the gelatin is cross - linked across the seam , illustrated as block 210 , forming a soft gel . the soft gel is then cured or dried according to the art , illustrated as block 212 , such as in a drying tunnel and further dried with lint - free cloths . the amount of fill may be controlled to allow for potential draw of glycerin and water into the fill from the shell of the soft gel . for example , the anhydrous magnesium salt may act to pull glycerin and water from the shell of the soft gel , thereby increasing the total volume within the soft gel . this increase in volume if not accounted for could cause the soft gel to rupture . thus , by controlling the volume of fill and accounting for potential draw , the soft gel can accommodate certain increases of pressure / volume without rupturing . in other embodiments , the filling of the soft gel may be any emulsified mineral supplement . for example , combinations of natural products and synthetic chemicals ; anything that tastes bad yet is therapeutic because of being too bitter or other off taste ; anything that needs to be protected from light and oxygen ; anything that needs to be protected from oxidation ; anything that needed precise dosing yet has a liquid or emulsion as an acceptable or preferred delivery system . any suspension or liquid of sufficient viscosity to flow through the soft gel filling machine may be used . although the illustrative embodiments are various magnesium complexes , it will be appreciated by one skilled in the art that the soft gel capsule according to the disclosure can be utilized for any active pharmaceutical ingredient that would benefit from a soft gel encapsulation that prevents weeping of the pharmaceutical formulation . it will also be appreciated by those skilled in the art that the soft gel capsule can be utilized for dietary supplements , vitamin and mineral formulations and naturally derived compositions , such as fish oils and the like . although the devices , systems , and methods have been described and illustrated in connection with certain embodiments , many variations and modifications will be evident to those skilled in the art and may be made without departing from the spirit and scope of the disclosure . the discourse is thus not to be limited to the precise details of methodology or construction set forth above as such variations and modification are intended to be included within the scope of the disclosure . the terms and expressions which have been employed are used as terms of description and not of limitation , and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof , but it is recognized that various modifications are possible within the scope of the invention claimed . thus , it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features , modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art , and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims .
a stable soft gel dosage form for micronized magnesium complexes is provided wherein soft gel capsules containing various magnesium complexes can be stored for prolonged periods under typical home storage conditions with better than 98 % or 99 % asa integrity and with negligible physical or chemical deterioration of the soft gelatin capsule over an extended period of time . the stable soft gel capsule is sealed at a selected temperature forming a seam in which the gelatin promotes cross - linking across the heat seam . this method of sealing the soft gel provides for a better seal that cures the weeping problem that can result from the prior methods of heat sealing soft gel capsules .