Encapsulation: Product development by coating particles

In this article, we will offer you a brief overview of Encapsulation: Product development by coating particles. The encapsulation process, also known as the coating process, has been utilized for over 60 years across various industries, including food, pharmaceuticals, feed, and metals. This process employs liquid and solid ingredients to create an effective barrier against environmental or chemical interactions until a desired release occurs.

In the food industry, the coating process is commonly used in dry flavor production. Raw flavor compounds can easily become sticky or deteriorate under ambient temperature and moisture conditions. Therefore, encapsulation technology is essential for locking flavoring components within a dry, free-flowing coating layer. For dairy production, this coating process protects milk powder from oxidation and prevents unwanted odors.

Beyond protecting core ingredients, coating and encapsulation processes offer several advantages:

1. Controlling Release Rates: Encapsulation allows for the controlled release of coated ingredients. For example, it enables slow-releasing fertilizers and the gradual release of citric acid during sausage manufacture.
2. Enhancing Stability: Coating improves stability against temperature, moisture, oxidation, and light. This includes creating oxidation barriers for cocoa powder and beta-carotene, as well as providing protection during freeze and thaw cycles to extend shelf life.
3. Masking Undesirable Flavors: Encapsulation can effectively mask undesirable flavors. For instance, it can mask the smell of protein in infant milk powder or the taste of potassium chloride in nutritional supplements.
4. Improving Particle Morphology: The coating process enhances particle properties by preventing lumping, improving flowability, reducing dustiness, and modifying particle density.

Through these advantages, encapsulation technology plays a crucial role in product development across multiple sectors, ensuring quality and performance in the final products.

n our field testing area, we can apply coatings to small particles, granules, and related solid materials using various instruments. We have both pan coaters and drum coaters available for different coating processes. These instruments allow us to apply a variety of coating conditions, ranging from low to high temperatures, using both aqueous and non-aqueous coating materials.

In our laboratory, we test coating strength after encapsulation under dynamic conditions, such as pneumatic conveying or rotating drum methodologies, as well as under static conditions using a strength tester. The phenomenon of controlled-release or slow-release, well-known in the pharmaceutical industry and crop protection, enables dosage over an extended period. In some cases, coatings also improve powder flow by creating a smoother or more inert surface.

After the coating and encapsulation process, several analytical measurements can determine the quality of the coating layer. For example, SEM-EDX coupled with a microtome assists in determining coating thickness. All these aspects can be thoroughly investigated in our laboratory.

Coating and encapsulation of particles are applied across various industries, including food, feed, pharmaceuticals, and medical devices. We have collaborated with a wide variety of customers and are happy to assist with your inquiries regarding encapsulation processes and product development.