A spreader box and method form a bi-laminar paintball shell material. Walls of a box body define a reservoir containing, and an aperture dispensing, a first gel. Walls of a gate body define a reservoir containing, and an aperture dispensing, a second gel. Within the box, the first gel is kept separate from the second gel. The box body aperture dispenses the first gel as a continuous first layer. The gate body aperture dispenses the second gel as a continuous second layer that is adjacent and juxtaposed with the first layer, such that the first gel bonds with the second gel to form the bi-laminar paintball shell material. A paintball, containing a fill material, has a frangible bi-laminar shell including an exterior shell that completely surrounds and contains an interior shell. The paintball is adapted to withstand the normal range of forces sustained in being fired from a paintball gun.

A fill material is for use within a closed interior chamber of a gelatin paintball capsule. The fill material includes a polyethylene glycol and an oil. Each one of the polyethylene glycol and the oil is present in a respective amount that is substantially less than about 90% by weight of the fill material. The fill material additionally includes at least a first additive that is selected from the group consisting of an emulsifier, a dye, a density agent, a thickener, and a surfactant. Preferably, a starch may be used as the density agent, as the emulsifier, and/or as the thickener. Suitable starches may include corn starch, rice starch, potato starch, modified starch, and combinations thereof, among others.