Advanced Microencapsulation

ADVANCED MICROENCAPSULATION WITH A CONTROLLED RELEASE FUNCTION

We developed cutting-edge microencapsulation technology that offers a high-volume and cost-effective production of programmed-shell microcapsules with timed and controlled release functions. We create smart encapsulations for superior active delivery and bring product effectiveness to the next level.

Microcapsules are an imperceptible solution to noticeable problems.

Microencapsulation is a complex technique that involves incorporating active compounds – liquids, solids or gases – in tiny protective spheres (microcapsules) having an average diameter as small as Ø 0.5 to 10 µm. The microcapsules look like powder to the naked eye. The coating (shell), which is smaller than the width of human hair, creates a barrier isolating and protecting active compounds from the external environment.

We can programme the microcapsule shells to allow the controlled release of encapsulated substances – release at the right place and at the right time, and under certain conditions to suit specific needs. We are the only ones on the market producing programmed-shell microcapsules.

IT’S NOT JUST ANOTHER MICROENCAPSULATION

Our coaxial electrospray technology is the most technologically advanced microencapsulation solution.

Different microencapsulation techniques are currently available on the market, which include emulsion spray-drying, microemulsification, liposomal and microfluidic microencapsulation. However, the widespread emulsion spray-drying and microemulsification techniques are technologically limited solutions, producing emulsion microdroplets with no shells, which are not real microcapsules. The lack of shells makes the controlled and timed release impossible. The emulsification process also limits the selection of active substances.

While liposomes and microfluidic solutions are more advanced options, they are expensive, and their production rate is rather low. Also, although liposomal microencapsulation offers some flexibility with regard to the shell design, liposomes are highly unstable, and the choice of active substances is limited. While microfluidic technology allows for flexible microcapsule design with programmed shells, it is a costly technique, making it difficult to use beyond research purposes.

Our advanced microencapsulation technology combines the best of all the available techniques. From a technological point of view, it is on par with microfluidics, and with regard to production volumes and costs, it is in the same range as spray-drying and microemulsification.

Comparaison between advanced microencapsulation technology and emulsification

WE INTRODUCE CONTROLLED-RELEASE MICROCAPSULES

We bring microencapsulation to the next level. We are pioneering real microcapsules, where active substances are placed inside tiny spheres with programmed shells, providing protection from the external environment and allowing their controlled and timed release.

We can precisely programme the release time of active substances, offering enhanced functionality and achieving efficacy at an entirely different level. Such competitive advantages are the result of our long-standing experience and leading position in scientific research.

Today, the continuous (slow) of active substances is not new to the market. But the release at a defined point in time is a very complex task. None of the existing technologies can do that. Our technology can.

We can also programme the microcapsule opening triggered by external stimuli. Our technology is a game-changer on the market.

Our advanced microencapsulation technology is the only one on the market which produces programmed-shell microcapsules with a complex shell design that can open and release active substances according to predefined scenarios:

TIMED RELEASE

We programme the microcapsules’ shells to release active substances with high precision (release at a specific time of the day).

PROLONGED RELEASE

We can programme the microcapsules’ shells to ensure the constant and prolonged release of active compounds over a long period of time, up to several months.

SLOW/FAST RELEASE

Active substances can be released slowly or immediately.

TRIGGERED RELEASE

Active compounds are released under certain circumstances (release on demand). The microcapsule opening can be triggered by environmental conditions (change in temperature or pH), mechanical action (friction and other forces) or external stimuli (ultrasound, UV light).

We ensure the controlled release by varying polymers’ composition and density, and shells’ thickness.

We can design programmed-shell microencapsulation solutions of any complexity for a wide range of products (dietary supplements, pharmaceuticals, food and beverages, cosmetics, sports nutrition and others).

NO LIMITATION FOR ACTIVE SUBSTANCES

We can encapsulate practically any active substance, liquid, solid or gases, including small molecules and microelements.

FDA-APPROVED BIOCOMPATIBLE AND BIODEGRADABLE POLYMERS

For microcapsule shells, we can choose from a broad selection of FDA-approved biocompatible and biodegradable polymers: synthetic or semi-synthetic polymers (PLA, PCL, PLGA, etc.) or natural polymers (albumin, chitosan, alginate, agar-agar, gelatin, etc.). The shell polymers can be non-allergenic, tasteless, odourless, and 100% natural, making our microcapsules satisfy the specific needs of vegetarians, vegans and people with allergies.

The selection of the appropriate shell material will depend on the objectives and specific requirements, the final application of the product taking into consideration required microparticle size, properties of active compounds, environmental conditions, the required stability and release mechanism and manufacturing costs.

Our technology produces microcapsules of various sizes (Ø 0.5 to 10 µm). While the microcapsules offered today on the market often vary significantly in size, our technology produces uniform microcapsules with much smaller variations in size. We can make the shells mono- or multi-layered, depending on technological needs.

HIGH STABILITY

Unlike liposomes and emulsion droplets, our microcapsules are highly stable, making our technology suitable for a wide range of applications.

HIGH LOADING CAPACITY

Our microcapsules can hold high volumes of active substances (cargo-shell ratio up to 10:1).

LOW-COST SOLUTION

The production costs are mainly determined by the price of raw materials (polymers, encapsulated active substances) and represent a fraction of the final price of the product.

OUR COAXIAL ELECTROSPRAY TECHNOLOGY

Our patented coaxial electrospray technology produces micron- and submicron structures of a given geometry (spheres, fibres). To produce microcapsules, an active substance enters through the inner tube, and a polymer for the shell enters through the outer tube. Both are combined on the exit resulting in the controlled process of microencapsulation. This enables us to encapsulate a wide range of substances and achieve the required properties of the final product.

The production capacity of one industrial unit ranges from several kilos to several tons of microcapsules per month.

Mask taste, odour, colour, and texture

Mask taste, odour, colour and texture to improve palatability and product attractiveness.

Protect active ingredients

Protect active compounds from environmental conditions (moisture, oxidation, stomach pH, heat, sunlight, etc.) and interactions with other ingredients.

Improve bioavailability

Improve the bioavailability of active compounds to increase efficacy and allow optimal dosage delivery.

Increase stability

Increase the stability of active compounds resulting in the shelf-life extension.

Improve solubility and dispersibility

Increase solubility of the ingredients, especially of powdered forms, resulting in improved bioavailability.

Allow timed and targeted release

Controlled release of active substances at the right time and at the right place to improve efficacy, prolong action, and ensure optimal dosage.

Introduce new ingredients

Allow the introduction of new ingredients to broaden the applications and product range.

Make cost savings

Make redundant artificial flavourings, sweeteners, colourings, and other masking agents, as well as overdosing used to compensate for nutritional losses.