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What are some reasons to use microencapsulation or nanoencapsulation?
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Who makes microencapsulation and nanoencapsulation equipment?
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Does Southwest Research Institute (SwRI) manufacture microcapsules or nanocapsules?
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What are the biggest challenges in the microencapsulation and nanoencapsulation industries?
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How does SwRI help industry develop microencapsulation solutions?
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What role has SwRI played in the history of microencapsulation science and technology?
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Does SwRI offer training or workshops about microencapsulation?
1. What can I encapsulate?
A variety of active ingredients, whether solid or liquid, can be encapsulated. Gases may also be encapsulated in rare cases, which is limited due to technical difficulty. Feasibility is determined by the application and target specifications.
2. What are some reasons to use microencapsulation or nanoencapsulation?
- Conversion of liquids or tacky solids into free-flowing solids
- Separation of reactive components in mixtures
- Protection against the environment (oxygen, moisture, pH, etc.)
- Masking of odors or taste
- Controlled release or timed release
- Alters properties, i.e. crystalline into amorphous state
- Targeted delivery
3. What are some common shell materials?
There are hundreds of shell materials and thousands of variations and combinations. Common materials include waxes/fats, a wide variety of hydrocolloids, and other natural/synthetic polymers. Material selection is based on encapsulation technology, material properties/performance, economics, raw material supply, industry requirements and regulatory constraints. SwRI works closely with clients to down select the best candidates for consideration. A new formulation provides the best opportunity for intellectual property protection with a patent.
4. What sizes are microcapsules?
A common size range for conventional scalable microencapsulation is approximately 5 µm to 1 mm. Processes such as atomization and emulsion-based processes are ideal for particles in the range of a few microns to low hundreds of microns. Coextrusion and fluid bed coating are better suited for capsules that are at or above hundreds of microns. There are exceptions that can support smaller or larger than the common ranges.
5. How do I develop a microcapsule or nanocapsule?
SwRI takes a strategic approach to encapsulation system design, balancing the interdependent benefits and constraints between objectives such as capsule size, payload, morphology, process and materials. We recommend clients start a fixed encapsulation objective and then adjusting other variables around that anchor.
6. Can I encapsulate water or other aqueous fluids?
Fluids can be encapsulated, but their performance and stability are highly sensitive to the surrounding environment. Due to the small molecular size of water and its potential interaction with shell materials and other complications, the diffusion of water or osmotic pressure often results in capsules that fail to meet performance metrics.
7. How much does microencapsulation or nanoencapsulation cost?
Additional production scale processing costs for microencapsulation or nanoencapsulation can add tens of cents to tens of dollars (USD), depending on the materials, encapsulation design, process, storage, shipping, industrial application, regulations, and other fees or related unit operations (e.g. pre-processing, waste disposal, etc.).
8. Who makes microcapsules or nanocapsules?
Multiple domestic and international companies exist to manufacture of encapsulated ingredients. These companies offer rapid scalability with off-the-shelf formulations backed by proven performance but often with limited applications or flexibility. Most contract and toll manufacturers focus on one type of encapsulation process and may further limit their services to a single industry (e.g. food, pharmaceuticals, agriculture). In the absence of a toll or contract manufacturer that meets set criteria for an encapsulated product, many companies will set up their own internal encapsulation unit operations to have greater control and oversight of the process. SwRI is available to assist our clients in finding a contract manufacturer, finding a third party willing to host a new process, or help set up internal encapsulation production capabilities. As an independent and unbiased nonprofit organization, SwRI prioritizes the needs of our client when assisting with technology transfer and scale-up.
9. Who makes microencapsulation and nanoencapsulation equipment?
Equipment manufacturers exist for most encapsulation processes, though with varied limits on scale, lead times, cost and flexibility. SwRI has a broad range of off-the-shelf equipment from various manufacturers available to support client projects to evaluate processes and their feasibility. We can also assist with the modification of new/existing equipment or fabrication of new custom encapsulation equipment.
10. Does SwRI manufacture microcapsules or nanocapsules?
SwRI does not manufacture microcapsules or nanocapsules at a commercial sale. Capsules prepared at SwRI can be used for R&D, test trials, consumer testing, clinical trials and almost any purpose other than sale to a consumer. SwRI helps our clients set up their own manufacturing, find a toll/contract manufacturer, or identify a third party to host a new process if a toll/contract manufacturer is not available.
11. What are the biggest challenges in the microencapsulation and nanoencapsulation industries?
Water, oxygen and heat are three of the biggest challenges across all applications of encapsulation. The breadth of applications evaluated at SwRI gives us unique insight into these universal challenges, in addition to driving us to develop unique solutions to help overcome them. We frequently reach across industries to adapt solutions to a new application.
12. How does SwRI help industry develop microencapsulation solutions?
SwRI guides clients through a variety of encapsulation design steps, helping match the right technique and formulation to the specific industry application depending on sizes, payloads, morphologies, materials, costs and other variables. Process selection begins with understanding the objectives and specifications. We determine feasibility by matching the objectives with potential processes and materials.
13. What role has SwRI played in the history of microencapsulation science and technology?
SwRI is a pioneer in the field of microencapsulation, researching and developing microencapsulation technology since 1949. From the 1950s to the 1970s, the Institute was known for unique projects, such as encapsulating gasoline and pesticides, and for patenting co-extrusion and spinning-disk atomization techniques. By the 1980s, SwRI was well established as a leader in microencapsulation technology, and, in the 1990s to 2000s, SwRI became known for controlled release and pharmaceutical development under CGMP (current good manufacturing processes). Today, SwRI continues its legacy of advancing the field through client work, published research and training.
14. Does SwRI conduct training or workshops about microencapsulation?
SwRI has offered the Introduction to Microencapsulation Workshop for 10 years along with webinars and specialty trainings. The biannual workshop, which takes place at SwRI’s San Antonio campus, introduces participants to microencapsulation and nanoencapsulation, techniques and formulations, along with examples, equipment, strengths, weaknesses and the state of the art.