Formulations

Encapsulation of active ingredients and effect substances

This means that we encapsulate the active ingredient in polymer-based functional nano- or microparticles. Encapsulation allows us to "package" low-molecular substances such as fragrances or vitamins, but also proteins, antibodies and enzymes - while fully preserving their (bio)activity. Encapsulation enables the formation of a three-dimensional protective space for the active ingredient, as it is separated from its micro-environment by the surrounding shell. In this way, sensitive substances can be protected from oxidation, for example, and reactive agents from chemical reactions.

Spray drying

Spray drying is an established process in many industrial sectors such as pharmaceuticals, food science, chemistry and materials science. A solution, suspension or emulsion is converted into a solid powder form in a single process step. Especially for sensitive substances such as hormones, proteins or vitamins, spray drying is a very gentle method of drying and is also suitable for microencapsulation

Polymerization techniques

At the Fraunhofer IGB, customer-specific nano- and microparticles in the range of 200 nm – 10 μm are produced from commercially available polymers, depending on the problem at hand. Various polymerization techniques are used, such as miniemulsion polymerization or emulsifier-free emulsion polymerization.

Adjusting the release kinetics

By varying the particle size, the degree of loading, the molecular weight and the ratio of hydrophilic and hydrophobic monomer units, we can influence the release kinetics of the encapsulated substances in a customized manner. In this way, releases over very long periods (Ultralong Drug Release, ULDr) of three to four months can also be realized. Biodegradable compounds are of particular interest here, as these are completely metabolized or decomposed after their application in the body or in the environment.

By means of chemical modification, we specifically customize biopolymers such as gelatine, chitosan or inulin to suit different requirements depending on the area of application. By introducing a wide range of chemical groups, we can thus modify, for example, the viscosity, solubility or charge of the biopolymer in a targeted manner, enabling processes to be tailored more sustainably and efficiently.

Modified biopolymers

The polymer nanoparticles can be additionally functionalized on the surface for complex applications. For example, the particles produced at Fraunhofer IGB are modified on their surface via free carboxy groups using conventional coupling methods for the targeted transport of active ingredients in the body (drug targeting). Proteins have already been successfully bound to the nano- and microparticle surface via carbodiimide couplings and other cross-linking chemicals. The design of the particle surface aims to keep the proportion of unspecific binding very low. In addition to biodegradable nano- and microparticles, we are developing biosynthetic nanoparticles that simulate the conditions on cell surfaces (NANOCYTES^®).

NANOCYTES^® – Bifunctional core-shell particles

Potential for medicine

The encapsulation of active ingredients opens up innovative paths for medical applications, from personalized therapies to precise diagnostic methods. With encapsulation techniques, we can develop particles for the treatment of various diseases that are able to deliver active ingredients into cells in a targeted manner. The encapsulation of cancer drugs in particles also enables the targeted delivery of active substances to cancer cells, thereby protecting healthy tissue and increasing the efficiency of the therapy. In vaccine development, the encapsulation of vaccine components can increase stability and control the release of active ingredients for an improved immune response.

Tailor-made formulations for agricultural food and raw material production

Plant protection products such as pesticides, fungicides and herbicides as well as plant growth regulators are used in agriculture to protect plants from diseases and pests and to increase crop yields. Agricultural production also has a direct impact on soil, water and the atmosphere. Modern and sustainable agriculture that conserves resources, protects the environment and is economical at the same time is possible when active ingredients and effect substances are applied in a customized formulation.

Encapsulation protects active and effect substances from external influences on the one hand, while on the other hand we are able to release the encapsulated substances in a targeted manner as required thanks to the functional properties of the capsule material:

•  Pesticides and herbicides encapsulated in microparticles reach the target organisms directly and in a controlled manner. Pests and weeds can thus be controlled in a targeted and effective manner and the environmental impact reduced.
• Fertilizers formulated in microcapsules provide nutrients in a form that is easily available to plants.
• Microparticles in coatings when sowing seeds can supply the seeds with nutrients or other substances and thus promote germination and early plant growth.
  

Encapsulation can significantly reduce the amount of active and effect substance to be applied. We can also control the release of the substance, for example only when it rains. For use in agriculture, we choose bio-based and biodegradable polymers such as chitosan, inulin or alginate as the capsule material. Once the active ingredients have been released, they are simply broken down in the soil.

With our comprehensive expertise in material selection and process management, we develop solutions for formulation issues from a wide range of application areas and customized formulations for our customers. Please contact us with your requirements or your idea. We will then also support you with the industrial implementation.