Novel microcapsule designs and manufacturing processes
Lead Research Organisation:
University of Birmingham
Department Name: Chemical Engineering
Abstract
Abstracts are not currently available in GtR for all funded research. This is normally because the abstract was not required at the time of proposal submission, but may be because it included sensitive information such as personal details.
People |
ORCID iD |
| Zhibing Zhang (Principal Investigator) |
Publications
Al-Sharabi M
(2024)
Magnetic zinc oxide/silica microbeads for the photocatalytic degradation of azo dyes
in Colloids and Surfaces A: Physicochemical and Engineering Aspects
Al-Sharabi M
(2025)
Multicore silica microcapsules containing a-tocopherol for potential consumer product applications
in Materials Advances
Baiocco D
(2024)
Environmentally friendly calcium carbonate-polydopamine microcapsules with superior mechanical, barrier, and adhesive properties
in Sustainable Materials and Technologies
Baiocco D
(2021)
Encapsulation of hexylsalicylate in an animal-free chitosan-gum Arabic shell by complex coacervation
in Colloids and Surfaces A: Physicochemical and Engineering Aspects
Baiocco D
(2021)
Microcapsules with a fungal chitosan-gum Arabic-maltodextrin shell to encapsulate health-beneficial peppermint oil
in Food Hydrocolloids for Health
Baiocco D
(2025)
Organic-Inorganic Multilayer Microcarriers with Superior Mechanical Properties for Potential Active Delivery in Fast-Moving Consumer Goods
in Industrial & Engineering Chemistry Research
Baiocco D
(2022)
Microplastic-Free Microcapsules to Encapsulate Health-Promoting Limonene Oil.
in Molecules (Basel, Switzerland)
| Description | Through our EPSRC-funded (EP/V027654/1) project, we have made significant advancements in the field of microencapsulation, particularly in the development of microcapsules using environmentally friendly, microplastic-free ingredients [1]. Leveraging innovative approaches, we have successfully engineered microcapsules with a dual-shell structure, incorporating both organic and inorganic shell materials [2] . This unique design not only enhances the mechanical strength and stability of the microcapsules but also provides enhanced barrier properties, functionality and versatility towards a plethora of potential applications. Moreover, our emphasis on sustainable materials has led to the formulation of stable core-shell microcapsules, laden with a hydrophobic active, with additional performance properties, such as enhanced superior adhesiveness to target delivery substrates, which is relevant to applications in laundry formulations [3] . Expanding on microcapsule characterisation, we have also demonstrated that it is possible to establish a relationship between the Young's moduli of whole microcapsules (Hertz model) and their shell material via mathematical modelling, based on the mechanical response data of microcapsules generated by micromanipulation [4]. Overall, our findings underscore the feasibility and potential of eco-friendly materials and advanced encapsulation techniques for sustainable solutions in diverse sectors such as cosmetics [5] and agrochemicals, thereby contributing to the global efforts towards greener industrial processes. In collaboration with our academic partners (EP/V027727/1, EP/V027646/1), we have produced a review of the contemporary literature surrounding the formation and release properties of microcapsules, evaluating their associated benefits, drawbacks, and potential applications, while being cognisant of the current pressing regulatory and energy-saving challenges [6]. We have identified key challenges in current microcapsule designs and microencapsulation processes, particularly the limitations of single-layered, petroleum-sourced shells. To address these shortcomings, we have successfully engineered novel organic-inorganic multi-layered microcapsules with exceptional mechanical performance, architectures that have never been reported in the literature before [7]. Additionally, our collaboration with project partners at the University of Leeds (EP/V027646/1) [8] has explored the potential of non-spherical microcarriers, potentially opening new pathways for the encapsulation of other actives. These advancements provide superior mechanical strength while minimising leakage, which may be particularly appealing for the encapsulation of phase change materials (PCM). Furthermore, this grant is advancing our scientific understanding, particularly in the encapsulation of small, hydrophilic active ingredients such as vitamins, one of the most significant challenges in modern industry [9]. We are also extending our eco-friendly formulations to develop sustainable, photocatalytically active microbeads [10], as demonstrated through our collaboration with our academic partners at the University of Cambridge (EP/V027727/1). Overall, we believe our findings will not only shape the direction of our future research but also serve as a source of inspiration for both academic and industrial professionals. 1. Baiocco, D. and Z. Zhang, Microplastic-Free Microcapsules to Encapsulate Health-Promoting Limonene Oil. Molecules, 2022. 27(21): p. 7215. 2.Baiocco, D., M. Al-Sharabi, B.T. Lobel, O.J. Cayre, A.F. Routh, and Z. Zhang, Eco-Friendly Fungal Chitosan-Silica Dual-Shell Microcapsules with Tailored Mechanical and Barrier Properties for Potential Consumer Product Applications. ACS Omega, 2024. 9(26): p. 28385-28396. 3.Baiocco, D., B.T. Lobel, M. Al-Sharabi, O.J. Cayre, A.F. Routh, and Z. Zhang, Environmentally friendly calcium carbonate-polydopamine microcapsules with superior mechanical, barrier, and adhesive properties. Sustainable Materials and Technologies, 2024. 41: p. e01001. 4.Baiocco, D., Z. Zhang, Y. He, and Z. Zhang, Relationship between the Young's Moduli of Whole Microcapsules and Their Shell Material Established by Micromanipulation Measurements Based on Diametric Compression between Two Parallel Surfaces and Numerical Modelling. Micromachines, 2023. 14(1): p. 123. 5.Al-Sharabi, M., B.T. Lobel, D. Baiocco, O.J. Cayre, Z. Zhang, and A.F. Routh, Multicore silica microcapsules containing a-tocopherol for potential consumer product applications. Materials Advances, 2025. 6(4): p. 1468-1477. 6.Lobel, B.T., D. Baiocco, M. Al-Sharabi, A.F. Routh, Z. Zhang, and O.J. Cayre, Current Challenges in Microcapsule Designs and Microencapsulation Processes: A Review. ACS Applied Materials & Interfaces, 2024. 16(31): p. 40326-40355. 7.Baiocco, D., B.T. Lobel, M. Al-Sharabi, O.J. Cayre, A.F. Routh, and Z. Zhang, Organic-Inorganic Multilayer Microcarriers with Superior Mechanical Properties for Potential Active Delivery in Fast-Moving Consumer Goods. Industrial & Engineering Chemistry Research, 2025. 8.Lobel, B.T., D. Baiocco, M. Al-Sharabi, A.F. Routh, Z. Zhang, and O.J. Cayre, Nonspherical Particle Stabilized Emulsions Formed through Destabilization and Arrested Coalescence. Langmuir, 2025. 41(1): p. 550-562. 9.Guan, Z., D. Baiocco, and Z. Zhang, Microscale Delivery Systems for Hydrophilic Active Ingredients in Functional Consumer Goods. WIREs: Wiley Interdisciplinary Reviews, 2024. (under review). 10.Al-Sharabi, M., D. Baiocco, B.T. Lobel, O.J. Cayre, Z. Zhang, and A.F. Routh, Magnetic zinc oxide/silica microbeads for the photocatalytic degradation of azo dyes. Colloids and Surfaces A: Physicochemical and Engineering Aspects, 2024. 695: p. 134169. |
| Exploitation Route | P&G Belgium has sponsored a short project (£39000) to exploit some of the new capsules made at Birmingham under industrial setting, and a new contract has been signed and the project is ongoing. Moreover, P&G has agreed to sponsor a new EngD project and PhD project to take forward the findings from this project further. |
| Sectors | Agriculture Food and Drink Chemicals Energy Environment Healthcare Pharmaceuticals and Medical Biotechnology |
| Description | Socioeconomic Impact: We believe that our research into advanced microencapsulation technologies is already demonstrating a potential socioeconomic impact beyond academia. The development of microplastic-free, environmentally and consumer-friendly microcapsules is directly addressing regulatory shifts and consumer demand for sustainable products, positioning the UK at the forefront of a rapidly evolving global market. The economic implications are substantial, given that particulate products contribute approximately £50 billion per year to the UK economy, across multiple sectors, including home care, pharmaceuticals, and agrochemicals. Industry and Policy Engagement: Our formulations towards biodegradable microcapsules, directly respond to legislative pressures, such as the EU's regulatory ban on polymeric and UK policymakers, non-degradable microbeads. Companies in the consumer goods industry are increasingly looking to replace petroleum-derived encapsulants with bio-based alternatives. Specifically, our strategic industrial partners, such as Givaudan and Procter & Gamble, have engaged with our findings, demonstrating growing interest in further exploring our regulation-compliant microencapsulated solutions. New Research Areas: Our work has catalysed the emergence of a new research direction at the intersection of material science, colloidal chemistry, and sustainable manufacturing. The novel multi-shell architectures we have developed are opening potential pathways for encapsulation of costly actives and, possibly, phase change materials for energy storage, which are extremely challenging. Moreover, advancements in mathematical modelling of microcapsule yielded a novel relationship between the Hertzian and inherent Young's modulus of the shell. |
| First Year Of Impact | 2024 |
| Sector | Agriculture, Food and Drink,Chemicals,Energy,Environment,Healthcare,Pharmaceuticals and Medical Biotechnology |
| Impact Types | Societal Economic |
| Description | Design of a novel encapsulation system of water soluble actives for industrial applications |
| Amount | £133,420 (GBP) |
| Organisation | Procter & Gamble |
| Sector | Private |
| Country | United States |
| Start | 02/2024 |
| End | 02/2027 |
| Description | Digital Tattoo: Using Programmable Ink to Create On-Body Displays |
| Amount | £201,921 (GBP) |
| Funding ID | EPSRC Reference: EP/X017834/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 01/2023 |
| End | 12/2024 |
| Description | Dispersion and Dissolution of Hydrocolloids |
| Amount | £551,385 (GBP) |
| Funding ID | EP/W029065/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 02/2023 |
| End | 01/2026 |
| Description | Encapsulation process development |
| Amount | £100,000 (GBP) |
| Organisation | FMC Corporation |
| Sector | Private |
| Country | United States |
| Start | 03/2023 |
| End | 04/2027 |
| Description | Microplastic-free based encapsulation |
| Amount | £100,800 (GBP) |
| Organisation | BASF |
| Sector | Private |
| Country | Germany |
| Start | 02/2021 |
| End | 02/2025 |
| Description | Novel microcapsule designs and manufacturing processes |
| Amount | £395,449 (GBP) |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 08/2021 |
| End | 09/2024 |
| Title | Data analysis software |
| Description | A software package previously developed has been updated which can analyse micromanipulation data (force versus displacement data generated from compression of single microparticles) and determine the values of mechanical strength parameters including rupture force, displacement at rupture, deformation at rupture, nominal rupture strength, nominal rupture tension, toughness, Young's modulus of whole particle, and Young's modulus of microcapsule shell material automatically. |
| Type Of Material | Data analysis technique |
| Year Produced | 2022 |
| Provided To Others? | Yes |
| Impact | The software has been commercialised by Microforce Measurement Ltd UK with a license from the University of Birmingham. |
| Description | EngD project |
| Organisation | FMC Corporation |
| Country | United States |
| Sector | Private |
| PI Contribution | My research has generated a strong interest from FMC. |
| Collaborator Contribution | The partner has appointed an industrial supervisor, and will host the student's visit to the company, and provide all essential facilities/chemicals to undertake this project. |
| Impact | Not yet. |
| Start Year | 2023 |
| Description | Lego-Inspired Glass capillary microfluidic device: a technique for bespoke microencapsulation of phase change materials |
| Organisation | Loughborough University |
| Department | Department of Chemical Engineering |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | Dr Dan Baiocco and I have collaborated with Dr Goran Vladisavljevic's group at Loughborough by measuring the mechanical properties of novel phase change capsules using a micromanipulation technique developed in my group, and produced a joint paper which has been submitted to ACS Applied Materials & Interfaces for publication. |
| Collaborator Contribution | Dr Goran Vladisavljevic's group has prepared phase change capsules and characterised their other properties. |
| Impact | No |
| Start Year | 2022 |
| Description | New EngD project |
| Organisation | BASF |
| Country | Germany |
| Sector | Private |
| PI Contribution | The publications from my research team had generated interests from BASF and a new EngD project was then set up. |
| Collaborator Contribution | My partner has appointed an industrial supervisor to meet a student regularly, to host the student's visit to BASF for 3 months each year and provided some chemicals/equipment to undertake certain experiments. |
| Impact | A patent has been filed and paper has been submitted to a journal. |
| Start Year | 2021 |
| Description | PhD project funded by P&G |
| Organisation | Procter & Gamble |
| Department | Procter & Gamble, Belgium |
| Country | Belgium |
| Sector | Private |
| PI Contribution | I am Principal Investigator of this new project and there is a new PhD student undertaking it. |
| Collaborator Contribution | P&G provides the funds to pay the total cost of the project. |
| Impact | A review paper titled 'Microscale Delivery Systems for Hydrophilic Active Ingredients in Functional Consumer Goods' (NANOMED-979) has been submitted to WIREs Nanomedicine & Nanobiotechnology. |
| Start Year | 2024 |
| Description | Research project funded by Proctor & Gamble |
| Organisation | Procter & Gamble |
| Department | Procter & Gamble, Belgium |
| Country | Belgium |
| Sector | Private |
| PI Contribution | I am PI and there is a postdoctoral researcher Dr Dan Baiocco who was appointed to undertake this project. |
| Collaborator Contribution | P&G has provided the funds. |
| Impact | The project has generated outputs which are interesting to P&G. |
| Start Year | 2024 |