Production of monodisperse polyurea microcapsules using microfluidics

Production of a food-grade pickering emulsion stabilized by pea protein-different phenolic acids

BACKGROUND

This study aimed to use pea protein isolate-phenolic acids (PPI-PA) to create novel functional stabilizers for Pickering emulsions. The stabilizers were produced by the covalent bonding of PPI with gallic acid (GA), ferulic acid (FA), coumaric acid (CA), and chlorogenic acid (CGA). Structural changes resulting from PPI-PA interactions were characterized using FTIR, XRD, SEM, and fluorescence spectroscopy. Antioxidant properties were also evaluated. The emulsifying activity index (EAI), emulsion stability index (ESI), contact angle, surface tension, ζ-potential, optical properties, and confocal microscopy were used to evaluate the Pickering emulsions stabilized by PPI-PA conjugates.

RESULTS

Including PA in the PPI structure significantly enhanced the emulsion characteristics of the protein. Structural analysis revealed changes in protein characteristics after interaction with PA. The highest DPPH scavenging activity was observed for the PPI-FA, with a value of 37.59 ± 1.01%. The ESI of PPI-GA, PPI-FA, and PPI-CGA samples was better than that of PPI-CA. The EAI values for PPI, PPI-GA, PPI-FA, PPI-CA, and PPI-CGA were 53.86, 50.82, 64.94, 57.06, and 72.24 m2 g-1, respectively. Considering the surface tension results, adding PA to the PPI structure effectively enhances the emulsion properties of the protein.

CONCLUSION

The results of this study indicate that PPI-GA, PPI-FA, and PPI-CGA are novel particles that can serve as effective food-grade stabilizers, enhancing the stability of Pickering emulsions. © 2025 The Author(s). Journal of the Science of Food and Agriculture published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry.

Fabrication of uniform biodegradable microcages with predesigned shape printed from microarrays for sustained release of small hydrophilic molecules

Drug delivery vehicles have aroused increasing attention over the years due to their ability to protect and control the release of encapsulated cargo. However, several challenges significantly limit their wide applications including poor size distribution, uncontrollable size and shape, and leakage of loaded small hydrophilic cargos. This work introduces a novel and scalable microarray-based printing technique for preparing uniform biodegradable "microcages" with predesigned shapes for encapsulating and controlling the release of small hydrophilic molecules. The drugs encapsulated in the microcage are centrally located within solid microparticles without being exposed to the surface or dispersed throughout the polymer matrix. Here, 5(6)-carboxyfluorescein (CF) as a small and hydrophilic model drug are successfully loaded into polylactide acid (PLA) microcages with the dry loading method. Additionally, blending polycaprolactone (PCL) with PLA increases the permeability of the microcage polymer shells for controlled release. A higher PCL content results in a faster release rate of the encapsulated drug. Approximately 28 pg of CF particles can be encapsulated within individual microcages. This microcage printing technique provides a novel, scalable method for producing uniform biodegradable microcages, extending microprinting beyond microfilms and microparticles. A unique dry loading approach, independent of drug solubility, further broadens its utility for diverse biomedical applications.

Regulation of mechanical properties of microcapsules and their applications

Microcapsules encapsulating payloads are one of the most promising delivery methods. The mechanical properties of microcapsules often determine their application scenarios. For example, microcapsules with low mechanical strength are more widely used in biomedical applications due to their superior biocompatibility, softness, and deformability. In contrast, microcapsules with high mechanical strength are often mixed into the matrix to enhance the material. Therefore, characterizing and regulating the mechanical properties of microcapsules is essential for their design optimization. This paper first outlines four methods for the mechanical characterization of microcapsules: nanoindentation technology, parallel plate compression technology, microcapillary technology, and deformation in flow. Subsequently, the mechanisms of regulating the mechanical properties of microcapsules and the progress of applying microcapsules with different degrees of softness and hardness in food, textile, and pharmaceutical formulations are discussed. These regulation mechanisms primarily include altering size and morphology, introducing sacrificial bonds, and construction of hybrid shells. Finally, we envision the future applications and research directions for microcapsules with tunable mechanical properties.

Microplastic label in microencapsulation field - Consequence of shell material selection

Plastics make our lives easier in many ways; however, if they are not appropriately disposed of or recycled, they may end up in the environment where they stay for centuries and degrade into smaller and smaller pieces, called microplastics. Each year, approximately 42000 tonnes of microplastics end up in the environment when products containing them are used. According to the European Chemicals Agency (ECHA) one of the significant sources of microplastics are microcapsules formulated in home care and consumer care products. As part of the EU's plastics strategy, ECHA has proposed new regulations to ban intentionally added microplastics starting from 2022. It means that the current cross-linked microcapsules widely applied in consumer goods must be transformed into biodegradable shell capsules. The aim of this review is to provide the readers with a comprehensive and in-depth understanding of recent developments in the art of microencapsulation. Thus, considering the chemical structure of the capsule shell's materials, we discuss whether microcapsules should also be categorized as microplastic and therefore, feared and avoided or whether they should be used despite the persisting concern.

Accurate detection of enzymatic degradation processes of gelatin-alginate microcapsule by 1H NMR spectroscopy: Probing biodegradation mechanism and kinetics

With an increase in the severity of environmental pollution caused by microbeads, the development of biodegradable microcapsules that can be applied in diverse fields has attracted significant attention. The degradation processes are directly related to biodegradable microcapsule creation with high stability and persistence. In this study, biodegradable microcapsules are synthesized via a complex coacervation approach using gelatin and alginate as the capsule main wall materials; additionally, enzyme-induced decomposition mechanisms are proposed by observing spectral changes in proton nuclear magnetic resonance (¹H NMR) analyses. Additional analytical techniques confirm the chemical structure, morphology, and size distribution of the synthesized capsules; these uniform spherical microcapsules are 20-30 μm in size and possess a smooth surface. In addition to characterization, the microcapsules were exposed to targeted enzymes to investigate enzymatic effects using short-term and long-term degradation kinetics. Close inspection reveals that determination of the degradation rate constant of the major components in the capsule is feasible, and suggests two types of 4-stage degradation mechanisms that are enzyme-specific. These investigations demonstrate that capsule degradation can be explored in detail using ¹H NMR spectroscopy to provide a viable strategy for monitoring degradation properties in the development of new biodegradable polymers.

Quid Pro Flow

How do you get into flow? We trained in flow chemistry during postdoctoral research and are now applying it in new areas: materials chemistry, crystallization, and supramolecular synthesis. Typically, when researchers think of "flow", they are considering predominantly liquid-based organic synthesis; application to other disciplines comes with its own challenges. In this Perspective, we highlight why we use and champion flow technologies in our fields, summarize some of the questions we encounter when discussing entry into flow research, and suggest steps to make the transition into the field, emphasizing that communication and collaboration between disciplines is key.

Fluorescent melamine-formaldehyde/polyamine coatings for microcapsules enabling their tracking in composites

This study aimed the development of fluorescent melamine-formaldehyde (MF)/polyamine coatings for labelling of prefabricated microcapsules and their tracking in composites. The composition of the fluorescent MF coatings was studied by FTIR spectroscopy, thermogravimetric analysis, and elemental analysis. The characteristics of the coatings and its deposition on different surfaces were investigated using optical and fluorescence microscopy and fluorescence spectroscopy. MF prepolymers were polymerised with tri- and polyamines yielding in fluorescent coatings without addition of fluorescent dyes. Both, MF/poly(ethylene imine) and MF/poly(vinyl amine) (PVAm) coated glass beads showed maximum fluorescence at an excitation wavelength of λmax = 360 nm with the emission maxima at λmax = 490 nm and λmax = 410 nm, correspondingly. The MF/PVAm polymer was coated on diuron-poly(methyl methacrylate) microcapsules and tracked in highly filled composites (water-based plaster/paint) to show its applicability. MF/polyamine coatings were identified as promising materials for the fluorescent labelling of prefabricated microcapsules.

A Comparative Study on the Self-Healing Characterizations and Formulation Optimization of Polyurea Coating

Self-healing materials, especially self-healing polyurea/polyurethane, to replace traditional coating has been of increasing interest in the past decade. The frequency of regular maintenance work can also be reduced as the coating is capable of forming bonds at ruptured sites. This reduces the cost of maintenance and the risk involved in workers engaging in maintenance work. The extremely short curing time of polyurea coating could potentially outweigh the cost due to its short down time. With a high self-healing efficiency, self-healing polyurea could be the ultimate choice of protective coating. This report aims to find the optimum formulation for fabrication of polyurea with a high self-healing efficiency. This is conducted by changing the composition of the components chosen for formulation of polyurea. The choice of isocyanate and amine is varied to explore its impact on chain mobility and microphase separation, which are important factors affecting self-healing efficiency. A series of characterizations, including ATR-FTIR, DSC, optical microscope and mechanical tester, is used to analyze the factors affecting the self-healing efficiency of fabricated polyurea and to eventually determine the best formulation. The ideal formulation of toluene 2,4 diisocyanate-amine (TDI-P1000) polyurea managed to achieve a self-healing of 42%. Further studies could be done to include multiple healing mechanisms after different area of polyurea to boost its self-healing efficiency after repeated healing.

Mini-Review of Self-Healing Mechanism and Formulation Optimization of Polyurea Coating

Self-healing polymers are categorized as smart materials that are capable of surface protection and prevention of structural failure. Polyurethane/polyurea, as one of the representative coatings, has also attracted attention for industrial applications. Compared with polyurethane, polyurea coating, with a similar formation process, provides higher tensile strength and requires shorter curing time. In this paper, extrinsic and intrinsic mechanisms are reviewed to address the efficiency of the self-healing process. Moreover, formulation optimization and strategic improvement to ensure self-healing within a shorter period of time with acceptable recovery of mechanical strength are also discussed. The choice and ratio of diisocyanates, as well as the choice of chain extender, are believed to have a crucial effect on the acceleration of the self-healing process and enhance self-healing efficiency during the preparation of polyurea coatings.

Nonaqueous Emulsion Polycondensation Enabled by a Self-Assembled Cage-like Surfactant

Nonaqueous emulsions are crucial for a range of applications based on water-sensitive systems such as controlled polymerizations requiring anhydrous reaction conditions and the stabilization of readily hydrolyzable reagents or pharmacologically active components. However, defined molecular surfactants to stabilize such nonaqueous emulsions are scarce. We introduce a self-assembled coordination cage, decorated with cholesterol functionalities, to serve as a molecular surfactant for various oil-in-oil emulsions of immiscible organic solvents. While the positively charged cage forms the amphiphile's polar moiety, the non-polar cholesterol appendices can bend in a common direction to stabilize the emulsion. Templated by the droplets, polycondensation reactions were carried out to produce microstructured polyurethane and polyurea materials of different particle sizes and morphologies. Further, the amphiphilic cage can encapsulate a guest molecule and the resulting host-guest assembly was also examined as a surfactant. In addition, the aggregation behavior of the amphiphilic cage in an aqueous medium was examined.

Enabling Technology for Supramolecular Chemistry

Supramolecular materials-materials that exploit non-covalent interactions-are increasing in structural complexity, selectivity, function, stability, and scalability, but their use in applications has been comparatively limited. In this Minireview, we summarize the opportunities presented by enabling technology-flow chemistry, high-throughput screening, and automation-to wield greater control over the processes in supramolecular chemistry and accelerate the discovery and use of self-assembled systems. Finally, we give an outlook for how these tools could transform the future of the field.

Microfluidic encapsulation for controlled release and its potential for nanofertilisers

Nanotechnology is increasingly being utilized to create advanced materials with improved or new functional attributes. Converting fertilizers into a nanoparticle-form has been shown to improve their efficacy but the current procedures used to fabricate nanofertilisers often have poor reproducibility and flexibility. Microfluidic systems, on the other hand, have advantages over traditional nanoparticle fabrication methods in terms of energy and materials consumption, versatility, and controllability. The increased controllability can result in the formation of nanoparticles with precise and complex morphologies (e.g., tuneable sizes, low polydispersity, and multi-core structures). As a result, their functional performance can be tailored to specific applications. This paper reviews the principles, formation, and applications of nano-enabled delivery systems fabricated using microfluidic approaches for the encapsulation, protection, and release of fertilizers. Controlled release can be achieved using two main routes: (i) nutrients adsorbed on nanosupports and (ii) nutrients encapsulated inside nanostructures. We aim to highlight the opportunities for preparing a new generation of highly versatile nanofertilisers using microfluidic systems. We will explore several main characteristics of microfluidically prepared nanofertilisers, including droplet formation, shell fine-tuning, adsorbate fine-tuning, and sustained/triggered release behavior.

Assessing the efficiency of essential oil and active compounds/poly (lactic acid) microcapsules against common foodborne pathogens

Essential oils' active compounds present great potential as a bactericidal agent in active packaging. The encapsulation in polymeric walls promotes their protection against external agents besides allowing controlled release. This work produced PLA capsules with three different active compounds, Cinnamomum cassia essential oil (CEO), eugenol (EEO), and linalool (LEO), by emulsion solvent evaporation method. Characterizations included SEM, Zeta potential, FTIR, TGA, and bactericidal activity against E. coli, S. aureus, L. monocytogenes, and Salmonella. The active compounds showed microbiological activity against all pathogens. CEO capsules showed superior colloidal stability. The active compounds' presence in all capsules was confirmed by FTIR analysis, with possible physical interaction between CEO, EEO, and the polymeric matrix, while LEO had a possible chemical interaction with PLA. TGA analysis showed a plasticizing effect of active compounds, and the loading efficiency was 39.7%, 50.7%, and 22.3% for CEO-PLA, EEO-PLA, and LEO-PLA, respectively. The capsules presented two release stages, sustaining activity against pathogens for up to 28 days, indicating a satisfactory internal morphology. This study presented methodology for encapsulation of antimicrobial compounds that can be suitable for active food packaging. CEO-PLA capsules regarding stability and antibacterial activity achieved the best results.

Droplet Microfluidics for Tumor Drug-Related Studies and Programmable Artificial Cells

Anticancer drug development is a crucial step toward cancer treatment, that requires realistic predictions of malignant tissue development and sophisticated drug delivery. Tumors often acquire drug resistance and drug efficacy, hence cannot be accurately predicted in 2D tumor cell cultures. On the other hand, 3D cultures, including multicellular tumor spheroids (MCTSs), mimic the in vivo cellular arrangement and provide robust platforms for drug testing when grown in hydrogels with characteristics similar to the living body. Microparticles and liposomes are considered smart drug delivery vehicles, are able to target cancerous tissue, and can release entrapped drugs on demand. Microfluidics serve as a high-throughput tool for reproducible, flexible, and automated production of droplet-based microscale constructs, tailored to the desired final application. In this review, it is described how natural hydrogels in combination with droplet microfluidics can generate MCTSs, and the use of microfluidics to produce tumor targeting microparticles and liposomes. One of the highlights of the review documents the use of the bottom-up construction methodologies of synthetic biology for the formation of artificial cellular assemblies, which may additionally incorporate both target cancer cells and prospective drug candidates, as an integrated "droplet incubator" drug assay platform.

Monodisperse Selectively Permeable Hydrogel Capsules Made from Single Emulsion Drops

Capsules are often used to protect chemical and biological entities from the environment, to control the timing and location of their release, or to facilitate the collection of waste. Their performance depends on the thickness and composition of their shells, which can be closely controlled if capsules are made from double emulsion drops that are produced with microfluidics. However, the fabrication of such double emulsions is delicate, limiting throughput and increasing costs. Here, a fast, scalable method to produce monodisperse microcapsules possessing mechanically robust, thin, semipermeable hydrogel shells from single emulsion drops is introduced. This is achieved by selectively polymerizing reagents in close proximity to the drop surface to form a biocompatible 1.6 μm-thick hydrogel shell that encompasses a liquid core. The size-selective permeability of the shell enables the growth of living yeast and bacteria in their cores. Moreover, if capsules are loaded with adsorbents, they can repetitively remove waste products from water. The simplicity and robustness of the capsule fabrication makes the process scalable and cost effective. It has thus the potential to extend the use of calibrated capsules possessing well-defined dimensions to cost sensitive fields, including food, waste water treatment, or oil recovery.

Textured Microcapsules through Crystallization

This work demonstrates the fabrication of surface-textured microcapsules formed from emulsion droplets, which are stabilized by an interlocking mesh of needle-like crystals. Crystals of the small-organic-compound decane-1,10-bis(cyclohexyl carbamate) are formed within the geometric confinement of the droplets, through precipitation from a binary-solvent-dispersed phase. This binary mixture consists of a volatile solvent and nonvolatile carrier oil. Crystallization is facilitated upon supersaturation due to evaporation of the volatile solvent. Microcapsule diameter can be easily tuned using microfluidics. This approach also proves to be scalable when using conventional mixers, yielding spikey microcapsules with diameters in the range of 10-50 μm. It is highlighted that the capsule shape can be molded and arrested by jamming using recrystallization in geometric confinement. Moreover, it is shown that these textured microcapsules show a promising enhanced deposition onto a range of fabric fibers.

Encapsulated Limonene: A Pleasant Lemon-Like Aroma with Promising Application in the Agri-Food Industry. A Review

Limonene, mainly found as a major component in Citrus spp., has been proven to possess a valuable potential as sustainable replacement to synthetic pesticides and food preservatives. This review intends to give a clear overview of the principal emerging applications of limonene in the agri-food industry as antimicrobial, herbicidal and antioxidant agent. To successfully use limonene in a greener agri-food industry, its preservation had become a top concern for manufacturers. In order to elucidate the most efficient and sustainable manner to encapsulate limonene, the different techniques and materials tested up to the present are also reviewed. In general, encapsulation conserves and protects limonene from outside aggressions, but also allows its controlled release as well as enhances its low water solubility, which can be critical for the discussed applications. Other parameters such as scalability, low cost and availability of equipment will need to be taken into account. Further efforts would likely be oriented to the elucidation of encapsulating sustainable systems obtained by cost-efficient elaboration processes, which can deliver effective concentrations of limonene without affecting crops and food products.

Fabrication and Characterization of a Low-Cost Microfluidic System for the Manufacture of Alginate-Lacasse Microcapsules

The development of microfluidics-based systems in the recent years has provided a rapid and controlled method for the generation of monodisperse microencapsulates for multiple applications. Here, we explore the design, manufacture and characterization of a low-cost microsystem for the encapsulation of the fungal laccase from Pycnoporus sanguineus CS43 in alginate microcapsules. Multiphysics simulations were used to overview the fluid behavior within the device and estimate the resulting capsule size. Polymethylmethacrylate (PMMA) sheets were used for final microsystem manufacture. Different flow rates of the continuous (Q_c) and discrete (Q_d) phases in the ranges of 83–293 mL/h and 1–5 mL/h, respectively, were evaluated for microcapsule fabrication. Universal Serial Bus (USB) microscope and image analysis was used to measure the final particle size. Laccase encapsulation was evaluated using spectrophotometry and with the aid of fluorescent dyes and confocal microscopy. Results showed microcapsule size was in the range of 203.13–716.00 μm and Q_c was found as the dominant parameter to control capsule size. There was an effective enzyme encapsulation of 65.94% with respect to the initial laccase solution.