Eco-Friendly Fungal Chitosan-Silica Dual-Shell Microcapsules with Tailored Mechanical and Barrier Properties for Potential Consumer Product Applications.

Commercial perfume microcapsules are becoming popular across the globe to fulfill consumers' demands. However, most of microcapsules rely on synthetic polymers and/or animal-sourced ingredients to form the shells. Therefore, replacement of the shell materials is imperative to minimize environmental microplastic pollution, as well as to meeting peoples' needs, religious beliefs, and lifestyles. Herein, we report a methodology to fabricate environmentally benign dual-shell (fungal chitosan-SiO2) microcapsules laden with fragrance oil (hexyl salicylate). Anionically stabilized oil droplets were coated with fungal chitosan via interfacial electrostatic interactions at pH 2, which were then covered by an inorganic coating of SiO2 produced via external alkaline mineralization of sodium silicate. Core-shell microcapsules with a spherical morphology were achieved. Under compression, dual-shell chitosan-SiO2 microcapsules yielded a mean nominal rupture stress of 3.0 ± 0.2 MPa, which was significantly higher than that of single-shell microcapsules (1.7 ± 0.2 MPa). After 20 days in neutral pH water, only ∼2.5% of the oil was released from dual-shell microcapsules, while single-shell microcapsules cumulatively released more than 10%. These findings showed that the additional SiO2 coating significantly enhanced both mechanical and barrier properties of microcapsules, which may be appealing for multiple commercial applications, including cosmetics and detergents.

Current Challenges in Microcapsule Designs and Microencapsulation Processes: A Review.

Microencapsulation is an advanced methodology for the protection, preservation, and/or delivery of active materials in a wide range of industrial sectors, such as pharmaceuticals, cosmetics, fragrances, paints, coatings, detergents, food products, and agrochemicals. Polymeric materials have been extensively used as microcapsule shells to provide appropriate barrier properties to achieve controlled release of the encapsulated active ingredient. However, significant limitations are associated with such capsules, including undesired leaching and the nonbiodegradable nature of the typically used polymers. In addition, the energy cost of manufacturing microcapsules is an important factor to be considered when designing microcapsule systems and the corresponding production processes. Recent factors linked to UN sustainability goals are modifying how such microencapsulation systems should be designed in pursuit of "ideal" microcapsules that are efficient, safe, cost-effective and environmentally friendly. This review provides an overview of advances in microencapsulation, with emphasis on sustainable microcapsule designs. The key evaluation techniques to assess the biodegradability of microcapsules, in compliance with recently evolving European Union requirements, are also described. Moreover, the most common methodologies for the fabrication of microcapsules are presented within the framework of their energy demand. Recent promising microcapsule designs are also highlighted for their suitability toward meeting current design requirements and stringent regulations, tackling the ongoing challenges, limitations, and opportunities.

Lego-Inspired Glass Capillary Microfluidic Device: A Technique for Bespoke Microencapsulation of Phase Change Materials.

We report a Lego-inspired glass capillary microfluidic device capable of encapsulating both organic and aqueous phase change materials (PCMs) with high reproducibility and 100% PCM yield. Oil-in-oil-in-water (O/O/W) and water-in-oil-in-water (W/O/W) core-shell double emulsion droplets were formed to encapsulate hexadecane (HD, an organic PCM) and salt hydrate SP21EK (an aqueous PCM) in a UV-curable polymeric shell, Norland Optical Adhesive (NOA). The double emulsions were consolidated through on-the-fly polymerization, which followed thiol-ene click chemistry for photoinitiation. The particle diameters and shell thicknesses of the microcapsules were controlled by manipulating the geometry of glass capillaries and fluid flow rates. The microcapsules were monodispersed and exhibited the highest encapsulation efficiencies of 65.4 and 44.3% for HD and SP21EK-based materials, respectively, as determined using differential scanning calorimetry (DSC). The thermogravimetric (TGA) analysis confirmed much higher thermal stability of both encapsulated PCMs compared to pure PCMs. Polarization microscopy revealed that microcapsules could sustain over 100 melting-crystallization cycles without any structural changes. Bifunctional microcapsules with remarkable photocatalytic activity along with thermal energy storage performance were produced after the addition of 1 wt % titanium dioxide (TiO2) nanoparticles (NPs) into the polymeric shell. The presence of TiO2 NPs in the shell was confirmed by higher opacity and whiteness of these microcapsules and was quantified by energy dispersive X-ray (EDX) spectroscopy. Young's modulus of HD-based microcapsules estimated using micromanipulation analysis increased from 58.5 to 224 MPa after TiO2 incorporation in the shell.

Relationship between the Young's Moduli of Whole Microcapsules and Their Shell Material Established by Micromanipulation Measurements Based on Diametric Compression between Two Parallel Surfaces and Numerical Modelling.

Micromanipulation is a powerful technique to measure the mechanical properties of microparticles including microcapsules. For microparticles with a homogenous structure, their apparent Young's modulus can be determined from the force versus displacement data fitted by the classical Hertz model. Microcapsules can consist of a liquid core surrounded by a solid shell. Two Young's modulus values can be defined, i.e., the one is that determined using the Hertz model and another is the intrinsic Young's modulus of the shell material, which can be calculated from finite element analysis (FEA). In this study, the two Young's modulus values of microplastic-free plant-based microcapsules with a core of perfume oil (hexyl salicylate) were calculated using the aforementioned approaches. The apparent Young's modulus value of the whole microcapsules determined by the classical Hertz model was found to be EA = 0.095 ± 0.014 GPa by treating each individual microcapsule as a homogeneous solid spherical particle. The previously obtained simulation results from FEA were utilised to fit the micromanipulation data of individual core-shell microcapsules, enabling to determine their unique shell thickness to radius ratio (h/r)FEA = 0.132 ± 0.009 and the intrinsic Young's modulus of their shell (EFEA = 1.02 ± 0.13 GPa). Moreover, a novel theoretical relationship between the two Young's modulus values has been derived. It is found that the ratio of the two Young's module values (EA/EFEA) is only a function on the ratio of the shell thickness to radius (h/r) of the individual microcapsule, which can be fitted by a third-degree polynomial function of h/r. Such relationship has proven applicable to a broad spectrum of microcapsules (i.e., non-synthetic, synthetic, and double coated shells) regardless of their shell chemistry.

Microplastic-Free Microcapsules to Encapsulate Health-Promoting Limonene Oil.

Fast-moving consumer goods (FMCG) industry has long included many appealing essential oils in products to meet consumers' needs. Among all, the demand for limonene (LM) has recently surged due to its broad-spectrum health benefits, with applications in cosmetic, detergent, and food products. However, LM is extremely volatile, hence has often been encapsulated for a longer shelf-life. To date, mostly non-biodegradable synthetic polymers have been exploited to fabricate the microcapsule shells, and the resulting microcapsules contribute to the accumulation of microplastic in the environment. So far, information on LM-entrapping microcapsules with a natural microplastic-free shell and their mechanism of formation is limited, and there is lack of an in-depth characterisation of their mechanical and adhesive properties, which are crucial for understanding their potential performance at end-use applications. The present research aims towards developing safe microcapsules with a core of LM fabricated via complex coacervation (CC) using gum Arabic (GA) and fungally sourced chitosan (fCh) as shell precursors. The encapsulation efficiency (EE) for LM was quantified by gas chromatography (GC) separation method. The morphology of microcapsules was investigated via bright-field optical microscopy and scanning electron microscopy, and their mechanical properties were characterised using a micromanipulation technique. Moreover, the adhesive properties of the resulting microcapsules were studied via a bespoke microfluidic device fitted with a polyethylene-terephthalate (PET) substrate and operating at increasingly hydrodynamic shear stress (HSS). Spherical core-shell microcapsules (EE ~45%) with a mean size of 38 ± 2 µm and a relatively smooth surface were obtained. Their mean rupture force and nominal rupture stress were 0.9 ± 0.1 mN and 2.1 ± 0.2 MPa, respectively, which are comparable to those of other microcapsules with synthetic shells, e.g., urea- and melamine-formaldehyde. It was also found that the fCh-GA complexed shell provided promising adhesive properties onto PET films, leading to a microcapsule retention of ~85% and ~60% at low (≤50 mPa) and high shear stress (0.9 Pa), respectively. Interestingly, these values are similar to the adhesion data available in literature for microplastic-based microcapsules, such as melamine-formaldehyde (50-90%). Overall, these findings suggest that microplastics-free microcapsules with a core of oil have been successfully fabricated, and can offer a potential for more sustainable, consumer- and environmentally friendly applications in FMCGs.

Improved volatile cargo retention and mechanical properties of capsules via sediment-free in situ polymerization with cross-linked poly(vinyl alcohol) as an emulsifier.

HYPOTHESIS: It is hypothesized that poly(vinyl alcohol) (PVOH) as an emulsifier destabilizes the insoluble molecular aggregates by increasing interparticle interactions and their tendency toward agglomeration into large particle aggregates during the encapsulation process of one-step in situ polymerization. Porosity of capsule shells is expected to decrease with reducing agglomeration tendency to allow dense packing of smaller insoluble aggregates. Cross-linking the polymer network further reduces shell permeability to improve the retention of volatile cargos. PVOH also modifies the short-range order of polymer network to bestow improved mechanical properties in addition to the shell thickening effect at appropriate synthesis conditions. EXPERIMENTS: PVOH was used to stabilize a heptane-in-water emulsion as a template for producing capsules via one-step in situ polymerization. Shell morphologies at different PVOH concentrations were compared. Physical freeze-thawing and chemical cross-linking were adopted separately to synthesize capsules with a volatile cargo, and its retention was characterized qualitatively by a solvatochromism-based fluorescent method and quantitative payload calculation. Mechanical properties of capsules were tested with micromanipulation. The effect of graphene oxide (GO) impregnation into capsules was studied with various co-emulsifiers. FINDINGS: When PVOH alone was used as the emulsifier for capsule synthesis, the higher its concentration, the more porous the shell structure was. At very low concentrations, visible pores were eliminated. Freeze-thaw cycles reduced the permeability of capsule shells when visible pores were absent. Chemical cross-linking with poly(acrylic acid) (PAA) significantly improved the retention of volatile cargo heptane. PVOH substantially reduced polymer sediment during capsule synthesis, which eliminated the tedious centrifugation procedure that normally would have followed. Superior mechanical strength of capsules was achieved with PAA cross-linked PVOH at appropriate conditions. The impregnation of aqueously dispersed GO into capsules was also promoted by using PVOH but not hydrocolloid emulsifiers.