Delivery formats and encapsulation: Experts emphasize sensory profile, stability and thermal protection

04 Aug 2022 --- As more consumers gain interest in dietary supplements and on-the-go formulations, the delivery format and encapsulation industry is expanding to meet these needs. NutritionInsight speaks with experts from Firmenich, PharmaLinea, Pharmoko Biotechnologies and Rousselot, who detail how this space is shifting to include, for example, sprays and direct sticks. They also stress that the modern consumer seeks convenience and an enhanced sensory experience.

Rousselot details that when considering target-specific groups such as children, the nutritional gummy is one of the delivery formats exhibiting the strongest growth, recording a CAGR of 56.8% between 2017 and 2021, according to Innova Market Insights data.

According to Firmenich, encapsulation technologies continue to adapt and develop to meet the requirements of the new and emerging categories.

“This is particularly relevant in plant-based meat alternative formulations which require a different approach to deliver not only the flavors of meat but also the sensory cues expected when replicating the cooking of a meat burger, like aroma, sizzle and color,” says Iain Beck, Firmenich Taste & Beyond VP of delivery systems.

“To meet this Flexitarian shift, Firmenich created DynaromeTR as a natural delivery system that allows tailored flavor release at elevated temperatures by customizing the composition of its lipid phase.”

Emerging formats, ingredients and concerns
Pharmako Biotechnologies details that novel delivery systems or formats have converged with three crucial current trends, including convenience and ecological concerns.

HydroCurc utilizing the LipiSperse technology is applied in powdered ready-to-drink products in sports nutrition and nootropics, Pharmako Biotechnologies details.“Modern consumers live in a world where immediacy is required. They like their products close at hand, and expect faster onsets of action than previously possible with dietary supplements. Delivery systems now offer novel formats which make supplementation easier and more convenient for these modern consumers,” says Eric Meppem, commercial director at Pharmako Biotechnologies.

Regarding environmental concerns, Meppem adds:, “Enhancing the absorption of nutrients and medicines is a way of addressing the challenge of using resources more sustainably.” 

According to PharmaLinea, there is growth in demand for convenient delivery formats.

“For several years now, non-pill forms (syrups, drops, sprays and sachets) have overtaken pill forms (capsules, tablets and softgels) in demand by customers and they are also exhibiting higher growth,” says Matevž Ambrožič, marketing and PR director at PharmaLinea. 

“However, since 2020, two other formats have taken off in client interest – sprays and direct sticks – filled with either liquid or orodispersible powder.”

“In terms of encapsulations or ingredient delivery systems, the emerging or lasting trend are self-emulsifying materials where active ingredients are trapped in fatty medium, liposomal ingredients, or various other encapsulation approaches.”

Micronization for ingredients
Pharmako Biotechnologies adds that the most interesting ingredients – such as quercetin, curcumin, resveratrol and vitamin D3 – are lipophilic and have very poor solubility in water. Delivery systems are required to enhance their absorption and subsequent efficacy. 

Firmenich notes that encapsulation technologies’ three main challenges are cost, legislation and functionality.“These are not a one size fits all solution and the right system needs to be carefully selected depending on various factors such as the active ingredient, the final dosage form (for example, tablet, capsule, powder for a drink and liquid spray), the end user,” states George Kokkinis, technical director at Pharmako Biotechnologies.

“We have seen various techniques such as micronization and complexing with cyclodextrin, but more modern techniques have been developed and are slowly finding their way into nutraceuticals.”

Stability, thermal protection and suitable sensorial profile
PharmaLinea details how its formats deliver delayed release, stability, thermal security and suitable sensory profile. 

“At the first level, we typically work with added-value materials, branded ingredients that often have systems in place that guard active ingredients against external factors and provide both added stability and often also masking undesired taste,” says Ambrožič.

“The second level is where we add the most value – it is the art of product development, joining several ingredients together in a product matrix that enables both stability and a great user experience in a complex delivery format such as liquids or orodispersible powders.

“Testing the stability of active ingredients at the end of shelf life is of the utmost importance to us and so is organoleptic testing with diverse focus groups, with blind testing of taste and texture,” Ambrožič adds.

Firmenich details that in terms of the sensory profile, by reducing or limiting the temperature exposure in manufacturing, it is possible to ensure the flavor profile remains as close as possible to the original creation.

“Essentially, encapsulation is used to protect the flavor against processing conditions or the natural environment and to control the moment of flavor release to when it matters most – typically on the palate, but also during in-home cooking or preparation,” details Beck.

“We can use different processes or technologies to deliver the required benefits based upon the physical properties of the encapsulating particle. For example, Firmenich’s Flexarome technology provides additional moisture or temperature stability by increasing the carrier’s particle size and formulation.”

Delayed release capsules
According to Rousselot, creating capsules with delayed active pharmaceutical ingredient (API) release occurs at the manufacturing level, but successful formulation starts with a high-quality gelatin excipient.

PharmaLinea adds that for finished dosage forms, the future is the development of products that avoid undesired ingredients such as preservatives, sugars and colors.“Delayed release capsules only represent a limited number of delivery forms. For the vast majority, the general goal is to allow the capsule’s outer shell to dissolve quickly, something that can be limited if the excipient’s molecules form strong chemical bonds with one another during processing, a process called cross-linking,” details Pierre-Albert Thomas, global director of Rousselot Functional Ingredients.

“In the presence of specific APIs like aldehydes, antioxidants, complex multi-vitamin or mineral mixes and metallic ions, this ‘cross-linking’ effect is especially prevalent. Rousselot’s StabiCaps gelatin could help manufacturers achieve functional properties and dissolution performance of their softgels, even with challenging APIs.”

Raw material modifications
Considering the shifts within the delivery format and encapsulation space, PharmaLinea adds that a larger number of small companies are undertaking raw material modifications.

“There is more variation, more added-value options for each ingredient, especially the ‘superstar’ ingredients such as vitamin C, vitamin K and iron. There is a lot of work done on oil-based ingredients, where oil functions as protection or oil components are fixed on a carrier (powdered oil),” says Ambrožič.

Meanwhile, Pharmako Biotechnologies notes that the most significant shift in the delivery format and encapsulation space in recent years is greater recognition. 

“More brands now understand the importance of bioavailability, and consumers also recognize it. Innovative brand companies are now applying this technology in many categories. HydroCurc utilizing the LipiSperse technology is applied in powdered ready-to-drink products in sports nutrition and nootropics,” details Meppem.

Clean label and gelatin
According to Rousselot, as shoppers grow increasingly environmentally conscious, gelatin empowers nutraceutical producers to create solutions with stronger sustainable credentials.

Pierre-Albert Thomas, Global Director Rousselot Functional Ingredients.“Using gelatin in their formulations, brands can help ensure the full and responsible use of animal products intended for human consumption,” says Thomas.

“The unmatched versatility of gelatin makes it the ideal ingredient to address several current trends. Take ‘clean label’ products, for example. The ingredient’s status as an all-natural, familiar and e-number-free ingredient makes it an ideal candidate for the minimally processed products that have become so popular with consumers in recent years.”

Challenges: Technology, regulations and costs
Firmenich details encapsulation technologies’ three main challenges are cost, legislation and functionality, and providing all within the sustainability framework, including reduced carbon footprint and energy and water usage.

With delivery forms entering the market for the first time, brands must also contend with a range of safety and suitability tests, Rousselot details. 

“For nutritional supplements, for example, producers must be able to show that their product will remain stable and ready for use after 12 months of storage, making the base stability of the excipient particularly important,” Thomas explains. 

According to PharmaLinea, the greatest challenge is ensuring the stability of advanced delivery formats, especially those with a liquid medium. 

“When sourcing ingredients, we face the challenge of finding both clinically supported sources to bring functional benefits and also can be included in various delivery formats,” says Ambrožič.

“There is also the regulatory challenge – if you include an existing substance in a delivery format that enables greater availability, regulatory authorities may demand that you confirm its safety in this form.”

One challenge producers face in this area relates to the manufacture of nutraceutical gummies – a delivery form popular with today’s consumers, Thomas explains.

“The traditional process used for creating gummies in the confectionery industry involves depositing the gelatin mixture into starch molds, which are re-used across multiple batches.” 

“However, due to the risk of cross-contamination linked to the re-use of the starch, this method is unsuitable for manufacturing gummies containing active ingredients, leaving brands with a sticky dilemma. In response to this challenge, Rousselot developed its SiMoGel. This solution allows the gelatin mixture to be deposited in silicone or metal molds and even directly into blister packs for optimal hygiene, safety and efficiency.”

By Nicole Kerr