Microencapsulation and Microspheres
Introduction to Our Microencapsulation and Microspheronization

 
 
Spraying
 
Powders and Naturally Occurring Granulates Often Present Problems
Powders or naturally occurring granulates frequently do not meet the requirements for either processing or use.  The reasons are varied, but include:
  • They lack free flowing qualities
  • They are unstable and degrade
  • They cannot be introduced into a complex product because of degradation
  • Actives are released immediately instead of in a controlled release
  • Grinding balls abrade machinery in addition to the product
  • Agglomeration occurs uncontrollably
  • Dosing is inaccurate
  • Presentation is not appealing
  • Acidic and caustic actives cannot be added to other product components
  • Hygroscopicity creates stability problems

The range of difficulties is wide and dependent on the industry and application.
 
 
Dispersion in liquids
 
Impact of These Problems
These properties are detrimental to efficient processing and product use and lead to agglomeration, inexact dosage, abrading with loss of material, low reproducibility of castings.
 
Pharmaceutical and nutraceutical applications require highly reproducible dosage and the controlled release of active agents and this can not be achieved with conventional powders and granulates.
 
Cosmetics require both performance and visual pop and these cannot be provided.
 
Agricultural products have exacting dissolution and/or dispersion profiles which are not met.
 
Food additives chemistries do not allow correct performance without encapsulation.
 
BRACE Microspheres
 
The solution to these Problems
The implementation of perfectly spherical microencapsulates or microspheres with exactly the same size (Monomodal Size Distribution) circumvents many of the disadvantages that are encountered while using powders and naturally occuring granulates. Further, the materials used to encapsulate or which form the matrix, provide the protection and release characteristics that are needed. These Microspheres (or microencapsulates) are free flowing and roll with very little friction, guaranteeing a dust free environment.  Formerly impossible mixtures can be made such as the addition of acids, caustics, surfactants, etc. with the spheres being protected by the encapsulating shell.  Visual appeal can be created to aid marketing teams. 

 
 

Production System

 Ultra Spherical Microspheres
 Microspheres and microencapulates with a monodisperse grain size distribution and the smallest divergence are manufactured.
  • Perfectly spherical spheres
  • Diameters between 30 µm and 6000µm
  • Non abrading therefore dust free
  • Free flowing, porous, large surface area, soft or rigid
  • Perfect for sphere forming of pharmaceuticals, bacteria, enzymes or other heterogeneous catalysts with or without coating
  • Production rates to 10,000 litres per hour per line
  • Laboratory through production equipment and contract manufacturing
 
 
The Patented Process
A liquid solution, melt, dispersion, sol, or suspension is gently pumped through a vibrating nozzle system where upon exiting, the fluid stream breaks up into uniform size droplets. The surface tension of these droplets moulds them into perfect microspheres in which solidification is induced during a short period of free fall. Solidification of the microencapsulates can be induced in a gaseous and/or liquid medium through cooling, drying or chemical reaction. There are no constraints on the type of liquid - i.e. molten material, solutions, dispersions, sols or suspensions can be used to manufacture perfectly spherical Microspheres and microencapsulates. Our decades of experience applying our patented technology in 6 different industries enables us to provide the means to overcome the most difficult client microencapsulation problems to produce the exact sphere size, hardness, performance characteristics, controlled release, chemical resistance, physical release, and processing strength that is required.

 
 
Multiple Nozzle head
 
Development, Equipment, and Contract Production Facilities
Because of the chemistry intensiveness in the application of our micoencapsulation technology, we offer complete formulation development and testing capabilities to prove out each of our problem solving solutions.
 
We design and manufacture laboratory through full scale production unit operations. Laboratory systems starting with the Spherisator S are available through pilot and ultimately production systems with capacities from a few kg/h to over 10,000 L/h per line.
 
We also produce client microspheres and microencapsulates for both market development through full scale production contracts according to the customer's specifications.
 
Solidificaiton and washing of spheres
 
Processing Characteristics
A monodisperse sphere size distribution is obtained with a constant laminar flow through the nozzle. Amplitude and frequency of the nozzle oscillation are held constant by a closed loop control circuit but both can be varied over a defined range to influence the sphere size. Both must be held constant during a production run for consistency. Microencapsulate production units have a minimal space requirement (15 to 40sq.feet) and their energy consumption is very low.  Operation is virtually noiseless during operation. Our systems operate at atmospheric pressure or slightly positive pressure and can be designed to be explosion proof according to the GLP/ GMP guide lines. Microsphere production units need practically no maintenance and are operated with minimal staffing. Units with fully automated controls and remote monitoring can be delivered as an option.

 
 
Product Types
 
Types of Microspheres
There are very few restrictions regarding the types of microspheres and microencapsulates that can be produced. Through the right combination of liquid precursor, solidification process and subsequent treatments, a wide variety of microspheres can be produced.

 
 

  • Dry metal oxide microspheres produced on the basis of a sol (Al2O3, ZrO2, HfO2,
    TiO2, CeO4, SiO2, and mixed oxides) can be used as highly sinteractive press-feed for the production of high-tech ceramics. Through calcining the pore size and surface area of the microspheres can be tailored within the client's exacting specifications. These Microspheres make excellent catalyst carriers, homogenous catalysts or filtering materials. Unusually effective and abrasion resistant microspheres for grinding other materials are made from sintered Al, Zr and Hf-oxides.

  • Microspheres produced from molten materials (inorganic, organic, alloys and polymers) can be used for dosing, proportioning, compounding, coloring and light stabilization.

  • Microspheres with dissolved or embedded active agents, with or without coatings, are used for numerous pharmaceutical, consumer care, and cosmetic products.

  • Soluble chemical compounds can be incorporated into microspheres by precipitation for use in agricultural, food, pharmaceutical and cosmetics industries.

  • Suspensions are used to produce probiotic microencapsulates and microspheres with embedded enzymes or bacteria.

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Vobis, LLC provides fabrication, evaporation and granulation components, and modular evaporation, granulation and pelleting systems.  We support our technologies with experienced engineering and testing services. Our fabrication services, evaporators, crystallizers, distillation systems, multiple effect evaporators, falling film evaporators, thin film, wiped film and short path evaporators, extruders, pellet mills, spheronizers, and spray dryers have proven themselves in multiple client applications.  Our formulation development and contract production services are available for Evaporation as well as Microencapsulation, Microsphere forming, and Granulation with Extrusion, Spheronization, and Microencapsulation.
ASME Fabrication, Evaporators, Thin- Film Evaporators, Ethanol Plant Fabrication, Distillation Systems, Short- Path Evaporators, Falling FIlm Evaporators, Multiple Effect Evaporators, Crystallizers, Solvent Recovery Systems, Mixers, Extruders, Spheronizers, Microencapsulation
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