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Microencapsulation

Protecting sensitive substances

Microencapsulation is a specialized particle‑engineering process designed to protect sensitive substances and stabilize challenging formulations. By embedding active ingredients or functional liquids within a solid matrix, microencapsulation reduces exposure to oxygen, light or moisture and enables controlled handling and further processing.

Encapsulation in the fluid bed or spouted bed – for powders and liquids

Microencapsulation is a specific variant of spray granulation and is ideally suited for protecting oxidation‑sensitive or volatile substances. The process forms compact particles with a reduced specific surface area, significantly limiting the contact area available for oxidative or environmental attack.

Microencapsulation can be applied to both powders and liquids and is therefore widely used in the pharmaceutical industry for stabilizing sensitive formulations.

Microencapsulation as part of integrated particle processing

In many applications, microencapsulation is not an isolated process step, but part of an integrated particle‑processing concept. Depending on product requirements, microencapsulation can be combined with:

  • Fluid bed or spouted bed processing

  • Spray granulation

  • Layering

  • Subsequent coating steps

The goal is not only to encapsulate the active substance, but also to define particle size, morphology, density and surface properties for the intended application.

How microencapsulation works

The microencapsulation of oils and other hydrophobic substances typically takes place in two controlled process stages:

Formation of a stable emulsion

In the first step, the liquid to be encapsulated is emulsified using a suitable emulsifier. This emulsion forms the basis of the later protective matrix.
The droplet size must be very small to ensure sufficient stability during the subsequent drying and solidification step.

Embedding into compact granules

In the second step, the stabilized droplets are dried and embedded into solid granules using spray granulation principles. The liquid is encapsulated within a solid matrix, resulting in compact, free‑flowing particles with defined structure and improved stability.

This two‑stage microencapsulation approach allows sensitive substances to be protected while maintaining good handling, dosing and downstream processing properties.

Microencapsulation at Glatt – from formulation to scale up

Are you planning a project in the field of microencapsulation?

With extensive experience in handling oxidation‑sensitive and complex substances, Glatt supports you throughout the entire process chain. In our Technology Center, we help you evaluate:

  • which process is best suited for your product
  • which functional and physical properties microencapsulated granules can achieve
  • how to support you from formulation of the liquid phase to industrial‑scale production

Testing, development and scale‑up can be performed in close cooperation with our experts – including on‑site trials at our Technology Center in Weimar.

Looking for the right microencapsulation approach for your product?

Contact us!