Encapsulation of lipophilic bioactive molecules by microchannel emulsification

Currently, much effort is being invested in novel formulations of bioactive molecules, such as emulsions, for pharmaceutical, food, and cosmetic applications. Therefore, methods to produce emulsions with controlled-size droplets of uniform size distribution have been developed. On this concern, a microfluidic device called the microchannel (MC) was used in this work for emulsification. This is a novel method for producing monodispersed emulsion droplets with very narrow droplet size distribution and low energy input, due to the spontaneous droplet generation basically driven by the interfacial tension, unlike other conventional emulsification processes. This technology provides the formulation of oil-in-water (O/W) emulsions containing lipophilic active molecules with increased bioavailability, which may be readily absorbed by the human body. MC emulsification enables the preparation of highly monodispersed O/W emulsions, which may be applied as enhancer on active molecules delivery systems, as well as in foodstuff. In this study, formulations of O/W emulsions loaded with bioactive molecules, such as beta-carotene and gamma-oryzanol, were prepared by the MC emulsification process. Refined soybean oil containing the dissolved lipophilic molecule and either sugar ester or gelatin solution (1 wt.%) were used as the dispersed and continuous phases, respectively. The emulsification process conducted using the asymmetric straight-through MC plate enabled the production of monodispersed O/W emulsions, resulting in beta-carotene-loaded O/W emulsions with average droplet size (d(av)) of 27.6 mu m and coefficient of variation (CV) of 2.3% and gamma-oryzanol-loaded droplets with d(av) of 28.8 mu m and CV of 3.8%. The highly monodisperse beta-carotene-loaded droplets were physically stable throughout the storage period observed, resulting in droplets with d(av) 28.2 mu m and CV of 2.9% after 4 months storage in darkness at 5 degrees C. Single micrometer-sized monodisperse emulsions loaded with beta-carotene were successfully formulated using the grooved MC emulsification, resulting in droplets with d(av) of 9.1 mu m and CV of 6.2%.