Microencapsulation: A Review
Mali Snehal D.*, Khochage Swapna R., Nitalikar Manoj M., Magdum Chandrakant S.
Department of Pharmaceutics, Rajarambapu College of Pharmacy, Kasegaon Tal. Walwa Dist Sangli. (India)
*Corresponding Author E-mail: snehalmali4@gmail.com
ABSTRACT:
Microencapsulation is a technique by which thin coatings of wall material are formed around the substances which may be solids, liquids or even gases, enclosed in microscopic particles. Microencapsulated products (micro particles) are the small entities that have an active agent know as the core material surrounded by a shell known as the coating material or embedded into a matrix structure. Several properties can be attained by macro packaging techniques; however, the uniqueness of microencapsulation is the smallness of the coated particles and their subsequent use and adaptation to a wide variety of dosage forms and not has been technically feasible. The reasons for microencapsulation are countless. Microencapsulation system offers potential advantages over conventional drug delivery systems and also established as unique carrier systems for many pharmaceuticals. Although significant advances have been made in the field of microencapsulation, still many challenges need to be rectified during the appropriate selection of core materials, coating materials and process techniques. The review covers encapsulation materials, coating material, classification of microcapsules, physics of release through the capsule wall and / or desorption from carrier, techniques of preparation, characterization/ evaluation of microspheres many uses to which microcapsules are put.
KEYWORDS: Microcapsules, Microspheres, Microencapsulation, Coating material, Polymerization, Controlled Release and Sustained Release.
INTRODUCTION:
Microencapsulation is a technique by which thin coatings of wall material are formed around the substances which may be solids, liquids or even gases, enclosed in microscopic particles. The origin of this technique is in the late 1930s as a cleaner substitute for carbon paper and carbon ribbons as sought by the business machines industry. In the 1950s, the paper and ribbons were developed that contained dyes in tiny gelatin capsules which were released on impact by a typewriter key or the pressure of a pen or pencil.
By delivering the agent to the target tissue in the optimal amount in the right period of time, maximum therapeutic efficacy, little toxicity and minimal side effects can be achieved. There are various approaches in delivering a therapeutic substance to the target site in a sustained controlled release fashion. One such approach is using microspheres as carriers for drugs.1
An appropriate motto for microencapsulation would be 'Small is better'. In its simplest form, a microcapsule is a small sphere with an uniform wall around it. The material inside the microcapsule is known as the core, fill, or internal phase, whereas the wall is called a shell, membrane or coating.2
Microspheres are considered as free flowing powders having biodegradable polymers. Microencapsulation process helps for controlling the release characteristics of different coated materials, converting the liquids to solids, changing the colloidal and surface properties and providing environmental protection. The advantage of microencapsulation is smallness of the coated particles and their subsequent use and adaptation to a wide variety of dosage forms and product application. Drug moieties can be widely distributed throughout the gastrointestinal tract, because of smallness of particles, thus potentially improving drug sorption.3, 4 Size of the microencapsulated products is considered as larger than 1 micrometer and up to 1000 micrometers in diameter.5 Commercially available microparticles contain 10-90% w/w core. In microencapsulation technology, the absorption rate of a drug can be controlled by controlling its rate of release from the dosage form.3
Core materials
It is the specific material to be coated, can be liquid or solid in nature. The liquid core can include dispersed and/or dissolved materials. The solid core can include active constituents, stabilizers, diluents, excipients and release-rate retardants or accelerators.1 Number of core materials can be encapsulated like that live cells, adhesives, flavors, agrochemicals, enzymes, pharmaceuticals.3
Coating materials6
The physical and chemical properties of the resultant microcapsules/microspheres depend on the selection of coating materials. They may be hydrophilic polymers, hydrophobic polymers (or) a combination of both. A number of coating materials have been used successfully; examples of these include alginates7, gelatin, polyvinyl alcohol, ethyl cellulose, cellulose acetate. It should form a film that is cohesive with the core material.
Coating material properties6, 8
· Controlled release under specific conditions.
· Stable towards core material.
· Inert toward active ingredients.
· Stable Film-forming, tasteless,
· Economical.
· The coating can be flexible, hard, thin etc.
· Soluble in an aqueous media or solvent, or melting.
Examples of coating materials: 9, 10, 11
· Water soluble resins – Starch, Gelatin, Gum Arabic, Hydroxyethylcellulose Polyvinylpyrrolidone, Carboxymethylcellulose, Methylcellulose, Arabinogalactan, Polyvinyl alcohol, Polyacrylic acid.
· Water insoluble resins – Ethylcellulose, Polyethylene, Polymethacrylate, Polyamide (Nylon), Poly (Ethylene Vinyl acetate) and cellulose nitrate, Silicones, Poly lactideco glycolide.
· Waxes and lipids – Paraffin, Carnauba, Spermaceti, Beeswax, Stearic acid, Stearyl alcohol, Glyceryl stearates.
· Enteric resins – Shellac, Cellulose acetate phthalate, Zein
Classification1:
Microcapsules can be classified on three basic categories according to their morphology as follows,
1. Mononuclear
2. Polynuclear and
3. Matrix types
Mononuclear (core-shell) microcapsules contain the shell around the core, while polynuclear capsules have many cores enclosed within the shell. In matrix encapsulation, the core material is distributed homogeneously into the shell material. In addition to these three basic morphologies, microcapsules can also be mononuclear with multiple shells, or they may form clusters of microcapsules.
Figure 1: Microcapsule and microsphere
(a)
(b)
Figure 2: Various configurations of (a) microcapsules and (b) microspheres.
Table1: Terminology of microencapsulation products30
Terminology |
Description |
Size range |
Schematic illustration |
Microcapsules |
Contain the shell around the core e.g, coating liquid nuclei with solid walls. |
μm |
|
Nanocapsules |
Same structure as microcapsules, but smaller. |
nm |
|
Microspheres or microparticles |
The core material is distributed homogeneously into the shell material The cores and walls are both solid having no clear distinction between them |
μm |
|
Nanospheres or nanoparticles |
Same structure as microspheres, but smaller. |
nm |
|
Liposomes
Niosomes |
Lipid wall often made of phospholipids and cholesterol. Subtypes: unilamellar (one lipid layer) and multilamellar (several lipid layers). Similar to liposomes but their membranes are made of synthetic amphiphylic molecules (Detergents). |
μm
to
nm |
|
Reasons for Microencapsulation 1-9:
The reasons for microencapsulation are countless. In some cases, the core must be isolated from its surroundings, as in isolating vitamins from the deteriorating effects of oxygen, retarding evaporation of a volatile core, improving the handling properties of a sticky material or isolating a reactive core from chemical attack. There are several reasons why substances may be encapsulated.2
1. To formulate a sustained or prolonged release of the drug.
2. To improve patient compliance by masking the unacceptable taste and odor.
3. To convert the liquid drugs in a free flowing powder.
4. To protect the drug from moisture, light and oxygen, e. g. Nifedipine
5. To prevent the incompatibility between drugs
6. To prevent the volatilization of drugs at room temperature like Aspirin and peppermint oil.
7. To reduce the toxicity and GI irritation produced with KCl and ferrous sulphate.
8. To change the site of absorption.
9. To isolate vitamins from the deteriorating effects of oxygen such as microencapsulated vitamin A palmitate had enhanced stability, as prevent from oxidation.
10. To prepare intrauterine contraceptive device.
11. To protect the immediate environment of the microcapsules from the active components.
12. To reduce the possibility of sensitization of factorial person such as insecticides.
Difficulties in Microencapsulation Technique:
· Incomplete or discontinuous coating
· Inadequate stability or shelf life of sensitive pharmaceuticals
· Non reproducible and unstable release characteristics of coated products
· Economic limitations
Microencapsulation Techniques: 5, 12, 13
In general microencapsulation techniques are divided into two basic groups, namely chemical and physical, with the latter being further subdivided into physicochemical and physico-mechanical techniques. The techniques are shown in table 2:
Table2: Different techniques used for microencapsulation:
Chemical processes |
Physical processes |
|
Physico-chemical |
Physico-mechanical |
|
· Suspension, dispersion and emulsion polymerization · Polycondensation · Solvent evaporation method |
· Coacervation · Layer-by-layer (L-B-L) assembly · Sol-gel encapsulation · Supercritical CO2-assisted microencapsulation |
· Spray-drying · Multiple nozzle spraying · Fluid-bed coating · Centrifugal techniques · Vacuum encapsulation |
Chemical Methods
In-situ processes such as emulsion, suspension, precipitation or dispersion polymerization and interfacial polycondensation are the most important chemical techniques used for microencapsulation.
Polymerization: 5, 12
It is a new in situ method of microencapsulation. In polymerization a liquid or gaseous phase is used as continuous or core material and involved reaction between them. As a result the polymerization reaction occurs at a liquid-liquid, solid-liquid, Liquid-gas, or solid-gas interface and form protective microcapsule coatings.
Interfacial polymerization technique: 14, 15
The microencapsulation of di-ammonium hydrogen phosphate (DAHP) by polyurethane-urea membrane was done using an interfacial polymerization method. Microcapsules are produced by the interfacial reaction of diphenyl methylene diisocyanate (MDI) which is dissolved in toluene and water at the interface of drops of the aqueous phase (containing DAHP) dispersed in the organic phase.
Interfacial polymerization method included the following steps:
(1) Dispersion of an aqueous solution (core material) in an oil phase,
(2) Addition of the wall-forming solution, and
(3) Growth of the membrane.
In the general procedure for the preparation of the microcapsules, the three solutions are used:
The organic phase (OP1) and the solution containing the core substance (W) are vigorously stirred using a homogenizer (8000 rpm) for 5 min at room temperature. The solution (OP2) of diisocyanate monomer (MDI) and catalyst (DBDL) is added to the primary emulsion. For the formation of the primary membrane, the mixture is stirred (700 rpm) for 10 min at room temperature. Then, stirring is reduced to 300 rpm and reaction lasts for 4 h allowing the membrane growth (630C). The microcapsule slurry is decanted and washed with toluene and water to remove unreacted MDI and non-encapsulated DAHP. The filtered microcapsules are dried at 400C for 24 h. The microcapsules are characterized by several techniques: elementary analysis, particle size distribution, FTIR spectroscopy, solid state NMR and thermal analysis.
Solvent evaporation method: 16, 17, 18
It consists of four major steps:
Figure 3: Basic steps of microencapsulation by solvent evaporation.
(1) Dissolution or dispersion of the drug in an organic solvent containing the polymer;
(2) emulsification of this organic phase, called dispersed phase, in an aqueous phase called continuous phase;
(3) Extraction of the solvent from the dispersed phase by the continuous phase, accompanied by solvent evaporation, transforming droplets of dispersed phase into solid particles; and
(4) Recovery and drying of microspheres to eliminate the residual solvent.
Other alternative methods of Solvent evaporation method:
The Other alternative methods of Solvent evaporation methods are shown below in figure 3
1. The w/o/w double emulsion method:
2. The o/w co-solvent method:
3. The o/w dispersion method:
4. The o/o non-aqueous solvent evaporation method
Physico-Chemical Methods:
Coacervation Method- 6, 4, 19
This process consists of three steps-
1. Formation of three immiscible phases
2. Deposition of the liquid polymer coating on the core material
3. Rigidizing of the coating material
Step-1: Formation of three immiscible phases
It involves the formation of three immiscible chemical phases: a liquid vehicle phase, a coating material phase and a core material phase.
Step-2: Deposition of the liquid polymer coating on the core material
It involves the controlled, physical mixing of the material in the manufacturing vehicle. The liquid polymer coating deposits upon the core material. Core material occurs if the polymer is adsorbed at the interface formed between the core material and the liquid vehicle phase, and this adsorption phenomenon is a prerequisite to effective coating.
Step-3: Rigidizing of the coating material
It involves rigidizing the coating material, usually by thermal, cross-linking or desolvation techniques, to form self-sustaining microcapsules.
Physico-Mechanical Methods:
Spray-Drying Method: 4, 20
This method is conducted by dissolving coating material in which core material is insoluble and dispersed in it. Then the mixture is atomized into an air stream which is usually heated. This air supplies the latent heat of vaporization to remove solvent from coating material. Thus the microencapsulated product is formed.
For example, Tramadol was complexed with a sulfonic acid cation-exchange resin by a column method. Microencapsulation of tramadol–resin complexes (TRC) was carried out by the spray-drying method.
The TRC were suspended into various EC organic solutions with constant magnetic stirring, then subsequently spray-dried in a laboratory spray dryer through a two-fluid pressure nozzle with a concurrent drying air flow. It was found that with the proper selection of solvent and viscosity-grade provide satisfactory sustained-release for the tramadol–resin complex.
Pan coating: 4, 21
The pan coating process is among the oldest industrial procedures for forming tablets and coated particles, widely used in the pharmaceutical industry. The particles are tumbled in a pan or other device while the coating material is applied slowly. For microencapsulation, solid particles greater than 600 microns in size are generally considered and are tumbled in a pan or other device and the coating material is applied slowly. The coating material is applied in the form of a solution, or as an atomized spray. The coating solvent is removed using warm air or drying in the oven.
In another way solid particles are mixed with a dry coating material. The temperature is raised so that the coating material melts and encloses the core particles, and then is solidified by cooling.
Co-Extrusion method: 4, 21
In this process, a jet of core liquid is surrounded by a sheath of wall solution or melt. A dual fluid stream of liquid core and shell materials is pumped through concentric tubes and forms droplets under the influence of vibration. The shell is then hardened by chemical cross linkings, cooling, or solvent evaporation. Different types of extrusion nozzles have been developed in order to optimize the process. The particles formed are in the range of 400– 2,000 μm (16–79 mils) in diameter. The drops are formed by the breakup of a liquid jet; therefore the process is only suitable for liquid or slurry.
Chemical crosslinking methods: 22, 23
The primary amine groups of chitosan are reacted with different crosslinking agents like a di-aldehyde (mostly glutaraldehyde, formaldehyde). The aqueous solution of chitosan with the drug is added in a water-immiscible solvent (e.g. liquid paraffin) containing a surfactant and the water-in-oil (w/o) emulsion is formed, after which glutaraldehyde of varying amount is added depending upon the crosslinking density required. And thus drug-loaded microspheres are obtained. The microspheres formed are filtered, washed with suitable solvents and dried. It has also been reported that glutaraldehyde crosslinking leads to the formation of microspheres with rough surface which can be overcome by using toluene saturated glutaraldehyde.
Characterization/ Evaluation of Microspheres: 1, 4, 24, 25, 26,
Sieve analysis
Mechanical sieve shaker is used to separate the microspheres into various size fractions. Five standard stainless steel sieves (20, 30, 45, 60 and 80 mesh) in a series are arranged in the order of decreasing aperture size. Drug loaded microspheres are placed on the upper-most sieve. The sieves are shaken for 10 min, and then the particles separated are weighed.
Morphology of microspheres
1. Optical microscopy:
This method is used to determine particle size by using optical microscope. The measurement is done under 100x (10x eye piece and 10x objective), 450x (10x eye piece and 45x objective) and 100 particles are calculated.
Microcapsule solvation can be predicted using following formula;
M1 - Microcapsules weighed immediately
M2 - After drying to a constant weight
2. Micromeritic properties:
a) Bulk density:
b) Tap density
Tap density is measured by employing the conventional tapping method or tap density apparatus using measuring cylinder and 100 tapings, taped density is calculated by following formula;
Compressibility index :
c) Hausnner’s ratio:
d) Angle of repose:
Accurately weighed microcapsules are passed through a funnel on the horizontal surface. The height (h) of the heap formed and radius (r) of cone base are measured. The angle of repose (θ) is calculated by following formula;
Where r is the radius and h is the height
3. Scanning electron microscopy (SEM):
SEM method is used to determine the surface morphology of microcapsule. With the help of double sided sticking tape, microcapsule are mounted directly on the SEM sample slub and coated with gold film under reduced pressure.
4. Microcapsule Percentage Yield :
Where M is the weight of microcapsules and Mo is the total expected weight of drug and polymer.
5. Drug Loading, and Encapsulation Efficiency:
Microspheres containing drug (20 mg) are crushed and then dissolve in distilled water with the help of ultrasonic stirrer for 3 hr, filter and assayed by UV-visible spectroscopy.
6. Swelling index: 4
Characterization of sodium alginate microspheres is performed with this technique. Alginate microspheres (100mg) are placed in a wire basket which is kept on the solution (100 ml) such as distilled water, buffer solution of pH (1.2, 4.5, 7.4) at 370 C and changes in weight between initial weight of microspheres and weight due to swelling is measured by taking weight periodically and soaking with filter paper.
7. Thermal analysis:
Thermal analysis of microcapsule and its component can be done by using-
Differential scanning calorimetry (DSC)
Differential thermometric analysis (DTA)
Thermo gravimetric analysis (TGA)
8. X-ray diffraction
This technique is used to determine the change in crystallinity of drug.
9. Stability studies
The microspheres are placed in screw capped glass container and stored at conditions:
1. Ambient humid condition
2. Room temperature (27 +/- 2 0C)
3. Oven temperature (40 +/- 2 0C)
4. Refrigerator (5 0C - 80C).
It is carried out for 60 days and the drug content and drug release of the microsphere are analyzed.
Release Mechanisms 21, 27
Mechanisms of drug release from microspheres are:
1. Degradation controlled monolithic system
The drug is dissolved in matrix and is distributed uniformly throughout. The drug is strongly attached to the matrix and is released on degradation of the matrix. The diffusion of the drug is slow as compared with degradation of the matrix.
2. Diffusion controlled monolithic system
Here the active agent is released by diffusion prior to or concurrent with the degradation of the polymer matrix. Rate of release also depend upon where the polymer degrades by homogeneous or heterogeneous mechanism.
3. Diffusion controlled reservoir system
Here the active agent is encapsulated by a rate controlling membrane through which the agent diffuses and the membrane erodes only after its delivery is completed. In this case, drug release is unaffected by the degradation of the matrix.
4. Erosion
Erosion of the coat due to pH and enzymatic hydrolysis causes drug release with certain coat material like glyceryl mono stearate, beeswax and steryl alcohol etc.
Table 3: List of the Techniques Used For Encapsulation of Different Core Materials
Core material |
Reason For Encapsulation |
Coating agent |
Technique used |
reference |
Ciprofloxacin |
Taste Masking Of Bitter Drugs |
Eudragit NE30D/RL30D, HPMC |
Wurster fluid bed coating |
8 |
Clarithromycin
|
Taste Masking Of Bitter Drugs |
Glyceryl monostearate, Eudragit E100 |
Spray congealing |
8 |
Chloroquine |
Taste Masking Of Bitter Drugs |
diphoshphate Eudragit RS100 |
Coacervation Phase seperation |
8 |
Tramadol |
Oral Sustained-Release |
ethylcellulose |
the spray-drying method |
20 |
Cisplatin |
Sustained Release |
chitin and chitosan |
w/o emulsion cross-linking method |
22 |
Verapamil Hydrochloride |
For Gastro Retention And Controlled Release |
Methocel K4M, Methocel K15M and Methocel K100M |
emulsion solvent evaporation technique |
31 |
Loxoprofen |
Sustained Release |
Ethylcellulose, |
Emulsion Solvent Evaporation Technique |
32 |
Rifampicin (RIF) |
Controlled Release |
Eudragit |
emulsion solvent diffusion method |
33 |
Clarithromycin |
For Gastro Retention |
Eudragit S 100, RS 100, RL 100, L 100 and L 100 55 |
emulsion solvent diffusion method |
34 |
Volatile Citronella Oil |
Sustained Release |
Chitosan |
Modified Orifice Method |
35 |
Repaglinide |
Controlled Release To Increase Residence Time In The Stomach |
Eudragit S |
Emulsion Solvent Diffusion Technique |
36 |
Garcinia fruit extract |
For Protection And Controlled Release Of Food Ingredients Like (-) Hydroxycitric Acid (HCA) |
whey protein isolate (WPI), maltodextrin (MD) |
Freeze drying technique |
37 |
potassium chloride |
Sustained Release, Minimize The Gastric Irritation |
Eudragit RS and RL |
solvent evaporation method |
38 |
metformin hydrochloride |
Controlled Release |
Pectins |
water in oil (w\o) emulsion solvent evaporation technique |
39 |
zedoary turmeric oil (ZTO) |
Sustained Release |
Hydroxypropyl methylcellulose acetate succinate (HPMCASHG), hydroxypropyl methylcellulose (HPMC-60SH4000) |
quasi-emulsion–solvent-diffusion method |
40 |
Clonazepam
|
Bioadhesive Drug Delivery System |
Gelatin-Chitosan |
- |
41 |
Amoxicillin GI |
Bioadhesive Drug Delivery System -Therapeutic Efficacy Of Drug Increases |
Ethylcellulose-Carbopol- 934P |
- |
41 |
Application of Microencapsulation: 4, 6, 8, 15, 28
1. General Application
1. Cell immobilization:
In plant cell cultures, Human tissue is turned into bio-artificial organs, in continuous fermentation processes.
2. Beverage production
3. Protection of molecules from other compounds:
4. Quality and safety in food, agricultural and environmental sectors.
5. Soil inoculation.
6. In textiles: means of imparting finishes.
7. Protection of liquid crystals
8. Most flavoring is volatile; therefore encapsulation of these components extends the shelf-life of products by retaining within the food flavours that would otherwise evaporate out and be lost. Some ingredients are encapsulated to mask taste, such as nutrients added to fortify a product without compromising the product’s intended taste
2. Controlled Release and Sustained Release Dosage Forms
It includes,
1. To mask the bitter taste of drugs like Paracetamol, Nitrofurantoin etc.
2. To reduce gastric and other gastro intestinal (G.I) tract irritations, e.g., sustained release Aspirin preparations have been reported to cause significantly less G.I. bleeding than conventional preparations.
3. A liquid can be converted to a pseudo-solid for easy handling and storage e.g. eprazinone.
4. Hygroscopic properties of core materials may be reduced by microencapsulation e.g., Sodium chloride.
5. Carbon tetrachloride and a number of other substances have been microencapsulated to reduce their odor and volatility.
6. Microencapsulation has been employed to provide protection to the core materials against atmospheric effects, e.g., Vitamin-A Palmitate.
7. Separation of incompatible substance has been achieved by encapsulation
8. Physicochemical evaluation characterization: The characterization of the microparticulate carrier is an important phenomenon, which helps to design a suitable carrier for the proteins, drug or antigen delivery. These microspheres have different microstructures. These microstructures determine the release and the stability of the carrier.
2. Medical application
1. Release of proteins, hormones and peptides over extended period of time.
2. Gene therapy with DNA plasmids and also delivery of insulin.
3. Vaccine delivery for treatment of diseases like hepatitis, influenza, pertusis, ricin toxoid, diphtheria, birth control.
4. Passive targeting of leaky tumour vessels, active targeting of tumour cells, antigens, by intraarterial/ intravenous application.
5. Tumour targeting with doxorubicin and also treatments of leishmaniasis.
Magnetic microspheres can be used for stem cell extraction and bone marrow purging.
6. Used in isolation of antibodies, cell separation, and toxin extraction by affinity
chromatography.
7. Used for various diagnostic tests for infectious diseases like bacterial, viral, and fungal.
3. Radioactive microsphere’s application
1. Can be used for radioembolisation of liver and spleen tumours.
2. Used for radiosynvectomy of arthiritis joint, local radiotherapy, interactivity treatement.
4. Cosmetics : 29
For cosmetic applications, organic acids are usually good solvents; chitin and chitosan have fungicidal and fungistatic properties. Chitosan is the only natural cationic gum that becomes viscous on being neutralized with acid. These materials are used in creams, lotions and permanent waving lotions and several derivatives have also been reported as nail lacquers.
5. Photography: 29
Chitosan has important applications in photography due to its resistance to abrasion, its optical characteristics, and film forming ability. Silver complexes are not appreciably retained by chitosan and therefore can easily be penetrated from one layer to another of a film by diffusion.
CONCLUSION:
Microencapsulation means packaging an active ingredient inside a capsule ranging in size from one micron to several millimeters. The capsule protects the active ingredient from its surrounding environment until an appropriate time. Then, the material escapes through the capsule wall by various means, including rupture, dissolution, melting or diffusion. Microencapsulation is both an art and a science. There's no ONE way to do it, and each new application provides a fresh challenge. Solving these riddles requires experience, skill and the mastery of many different technologies.
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Received on 25.06.2013 Modified on 02.07.2013
Accepted on 07.07.2013 © RJPT All right reserved
Research J. Pharm. and Tech. 6(9): September 2013; Page 954-961