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Micro- and nano-encapsulation techniques, such as microfluidization, spray drying, and centrifugal extrusion, have been widely utilized in various industries, including pharmaceuticals, food, cosmetics, and agriculture, to improve the stability, shelf life, and bioavailability of active ingredients, such as vitamin A. Emulsion-based delivery platforms offer feasible and appropriate alternatives for safeguarding, encapsulating, and transporting bioactive compounds. Therefore, there is a need to enrich our basic diet to prevent vitamin A deficiency within a population. This review focused on addressing vitamin A shortages, encapsulation techniques for improving the delivery of vital vitamins A and their food applications. Additionally, more studies are required to guarantee the security of nano-delivery strategies, as they proliferate in the food and beverage sector.

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This study developed functional white chocolate enriched with free (WC-F) and encapsulated ß-carotene using whey protein isolate (WPI) and pullulan (PUL) blends through spray drying (WC-SP), freeze drying (WC-LP), and coaxial electrospinning (WC-EL). The thermal properties, rheological properties, hardness, and color of the chocolates were evaluated, and the stability of ß-carotene was monitored over 4 months at 25 °C. No significant differences were found in melting profile temperatures among samples; however, WC-LP and WC-EL exhibited higher melting energies (30.88 J/g and 16.00 J/g) compared to the control (12.42 J/g). WC-F and WC-SP showed rheological behaviors similar to those of the control, while WC-LP and WC-EL displayed altered flow characteristics. Hardness was unaffected in WC-F and WC-SP (7.77 N/mm2 and 9.36 N/mm2), increased slightly in WC-LP (10.28 N/mm2), and decreased significantly in WC-EL (5.89 N/mm2). Over storage, melting point, rheological parameters, and hardness increased slightly, while color parameters decreased. ß-carotene degradation followed a first-order reaction model, with degradation rate constants (k) of 0.0066 day-1 for WC-SP, 0.0094 day-1 for WC-LP, and 0.0080 day-1 for WC-EL, compared to 0.0164 day-1 for WC-F. WC-SP provided the best ß-carotene retention, extending the half-life period by 2 times compared to WC-F (126.04 days vs. 61.95 days). Practical implications: The findings suggest that WC-SP, with its superior ß-carotene stability, is particularly suitable for the development of functional confectionery products with extended shelf life, offering potential benefits in industrial applications where product stability is crucial. Future research directions: Further studies could explore the incorporation of additional bioactive compounds in white chocolate using similar encapsulation methods, as well as consumer acceptance and sensory evaluation of these enriched products.

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Fish swim bladder (FSB) is a type of traditional nutraceutical, but the lack of high-quality drying methods limits its premium market development. In order to obtain optimal-quality dried FSBs from Chinese longsnout catfish, the effects of liquid nitrogen pre-freezing (LNF) and drying on the physical properties and flavor of FSB were evaluated. Four methods were used for FSB drying, including natural air-drying (ND), hot-air-drying (HD), LNF combined with freeze-drying (LN-FD), and LNF combined with HD (LN-HD). Color, collagen content, rehydration ratio, textural properties, and flavor characteristics (by GC-IMS, E-nose, and E-tongue) were measured to clarify the differences among four dried FSBs. The results showed that ND cannot effectively remove moisture from FSB as the final product showed a stronger sourness in taste. HD led to a decrease in the collagen content and the collapse of the fiber structure in FSB. Compared to HD, LN-HD showed a higher collagen content (0.56 g/g) and a different flavor fingerprint. FSB treated by LN-FD had better physical qualities in terms of an attractive color, a high collagen content (0.79 g/g), low shrinkage, a higher rehydration ratio (2.85), and a soft texture, while also possessing richer characteristic flavors. The application of LN-FD may help the optimization of the nutrition level, rehydration ability, mouthfeel, and flavor of dried FSB.

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Lyophilization (aka freeze drying) has been shown to provide long-term stability for many crucial biotherapeutics, e.g., mRNA vaccines for COVID-19, allowing for higher storage temperature. The final stage of lyophilization, namely secondary drying, entails bound water removal via desorption, in which accurate prediction of bound water concentration is vital to ensuring the quality of the lyophilized product. This article proposes a novel technique for real-time estimation of the residual moisture during secondary drying in lyophilization. A state observer is employed, which combines temperature measurement and mechanistic understanding of heat transfer and desorption kinetics, without requiring any online concentration measurement. Results from both simulations and experimental data show that the observer can accurately estimate the concentration of bound water in real time for all possible concentration levels, operating conditions, and measurement noise. This framework can also be applied for monitoring and control of the residual moisture in other desorption-related processes.

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Messenger RNA (mRNA) vaccines have revolutionized the fight against infectious diseases and are poised to transform other therapeutic areas. Lipid nanoparticles (LNP) represent the most successful delivery system for mRNA. While the mRNA-LNP products currently in clinics are stored as frozen suspensions, there is evidence that freeze-drying mRNA-LNP into dry powders can potentially enable their storage and handling at non-freezing temperatures. Previously, we successfully applied thin-film freeze-drying (TFFD) to transform a polyadenylic acid [poly(A)]-LNP formulation from a liquid suspension to dry powders. The poly(A)-LNP were structurally multilamellar spheres without blebs, but the mRNA vaccines in clinics are comprised of mRNA-LNP that are structurally spheres surrounded by a unilamellar lipid bilayer, with some containing blebs, and it was reported that the presence of blebs increases the sensitivity of mRNA-LNP to freeze-drying-induced stress. In the present study, using an influenza A virus hemagglutinin (HA) mRNA in LNP that were structurally similar to that in the COVID-19 mRNA vaccines currently in clinic, we studied the effect of TFFD on the physical properties, internal structure, as well as immunogenicity of the HA mRNA-LNP vaccine. We concluded that TFFD can be utilized to prepare dry powders of the HA mRNA-LNP, but a sufficient amount of excipients were needed to minimize changes in the physical properties, structure, and immunogenicity of the HA mRNA-LNP vaccine.

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This article investigates the effect of different microwave powers on the crosslinking behavior and microwave freeze-drying characteristics of wheat starch-lauroyl arginate complex during the microwave freeze-drying process. During microwave freeze-drying, as microwave power increased from 0.1 W/g to 0.9 W/g, the freeze-drying time of WS-LA was reduced by 50 %, while the uniformity of freeze-drying was not affected by its composition. In the research results obtained from DSC, Raman spectroscopy, Fourier-transform infrared spectroscopy (FTIR), XRD, and SEM analyses, with the microwave power increased from 0.1 W/g to 0.9 W/g, the enthalpy value of the melting peak of the WS-LA (wheat starch-lauric acid) composite decreased from 1.15 J/g to 0.62 J/g. The full width at half maximum (FWHM) value increased from 25.6 to 30.79. The ratio of absorbance at 1022/995 cm-1 increased from 1.0111 to 1.0707. The recrystallization (RC) value decreased from 8.77 % to 0.07 %. Additionally, in the microstructure, the size of WS-LA composite particles decreased accordingly. The above findings indicated that the increase in microwave power during microwave freeze-drying had a negative impact on the formation of the WS-LA complex and the ordering of its structure in the sample.

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Freeze-drying is a commonly employed method in the food industry to extend shelf life of products. However, this process remains time and energy consuming. While higher shelf temperatures accelerate the process, they also pose the risk of product damage. The microstructure of the product, influencing heat and mass transport, is a critical factor. This study aims to understand the impact of 3-dimensional (3D) structural parameters (pore size, shape and orientation) on local primary freeze-drying kinetics. Freeze-drying experiments were conducted with maltodextrin solutions (c1 = 0.05, c2 = 0.15 and c3 = 0.3 w/w) at different shelf temperatures (T1 = -11, T2 = -15 and T3 = -33 °C) with the use of a freeze-drying stage that allows in-situ visualization of the process inside a 4D-X-Ray computed tomography (XCT). The findings show the importance of understanding the microstructure in detail to optimize the sublimation time during the freeze-drying process. It is shown that for longitudinal pores, the orientation is a crucial parameter.

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The objective of this study was to evaluate the impact of various drying methods: freeze drying, vacuum drying, convection drying, and convection-microwave drying at microwave powers of 50 W and 100 W, along with process temperatures (40 °C, 60 °C, and 80 °C), on the drying kinetics, selected physicochemical properties of dried celery stems, and their grindability. The Page model was employed to mathematically describe the drying kinetics across the entire measurement range. Convection-microwave drying significantly reduced the drying time compared to the other methods. The longest drying duration was observed with freeze drying at 40 °C. The product obtained through freeze drying at 40 °C exhibited the least alteration in color coordinates, the highest antioxidant capacity, and the greatest retention of chlorophylls and total carotenoids. At a specific temperature, the quality of the product obtained from vacuum drying was slightly lower compared to that from freeze drying. The most substantial changes in the physicochemical properties of the dried product were observed with convection-microwave drying at a microwave power of 100 W. The drying method selected had a significant impact on the energy consumption of grinding, average particle size, and the grinding energy index of the dried celery stems; these parameters worsened as the drying temperature increased. The product with the best quality characteristics and disintegration parameters was achieved using freeze drying at 40 °C.

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This study evaluated possible utilization of infrared drying (ID) as an alternative to spray- (SD) and freeze-drying (FD) for fish skin-derived gelatins. Physical, functional, thermal, and spectroscopic analyses were conducted for characterization of the resulting gelatin powders. Energy consumption for the applied drying methods were 3.41, 8.46 and 25.33 kWh/kg for ID, SD and FD respectively, indicating that ID had the lowest energy consumption among the studied methods. Gel strength, on the other hand, was lower (398.4 g) in infrared-dried gelatin (ID-FG) compared to that (454.9 g) of freeze-dried gelatin (FD-FG) and that (472.7 g) of spray-dried gelatin (SD-FG). TGA curves indicated that ID-FG showed more resilience to thermal degradation. SDS-PAGE and UV-Vis spectra indicated that slight degradation was observed in the ß-configuration of ID-FG. ID-FG and SD-FG gelatins had the highest water holding capacity (WHC), protein solubility and transparency values compared to that of FD-FG. Morphological structures of the samples were quite different as shown by SEM visuals. Ultimately, the findings showed that infrared drying may be a promising alternative for gelatin processing, maintaining product quality and supporting sustainable practices in food and other industries.

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Lightweight materials that combine high mechanical strength, insulation, and fire resistance are of great interest to many industries. This work explores the properties of environmentally friendly alginate aerogel composites as potential sustainable alternatives to petroleum-based materials. This study analyzes the effects of two additives (tannic acid and montmorillonite clay), the orientation that results during casting, and the crosslinking of the biopolymer with glutaraldehyde on the properties of the aerogel composites. The prepared aerogels exhibited high porosities between 90% and 97% and densities in the range of 0.059-0.191 g/cm3. Crosslinking increased the density and resulted in excellent performance under loading conditions. In combination with axial orientation, Young's modulus and yield strength reached values as high as 305 MPa·cm3/g and 7 MPa·cm3/g, respectively. Moreover, the alginate-based aerogels exhibited very low thermal conductivities, ranging from 0.038 W/m·K to 0.053 W/m·K. Compared to pristine alginate, the aerogel composites' thermal degradation rate decreased substantially, enhancing thermal stability. Although glutaraldehyde promoted combustion, the non-crosslinked aerogel composites demonstrated high fire resistance. No flame was observed in these samples under cone calorimeter radiation, and a minuscule peak of heat release of 21 kW/m2 was emitted as a result of their highly efficient graphitization and fire suppression. The combination of properties of these bio-based aerogels demonstrates their potential as substituents for their fossil-based counterparts.

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The objective of this study was to investigate the nutrient composition of low-grade New Zealand commercial fish (Gemfish and Hoki) roe and to investigate the effects of delipidation and freeze-drying processes on roe hydrolysis and antioxidant activities of their protein hydrolysates. Enzymatic hydrolysis of the Hoki and Gemfish roe homogenates was carried out using three commercial proteases: Alcalase, bacterial protease HT, and fungal protease FP-II. The protein and lipid contents of Gemfish and Hoki roes were 23.8% and 7.6%; and 17.9% and 10.1%, respectively. The lipid fraction consisted mainly of monounsaturated fatty acid (MUFA) in both Gemfish roe (41.5%) and Hoki roe (40.2%), and docosahexaenoic (DHA) was the dominant polyunsaturated fatty acid (PUFA) in Gemfish roe (21.4%) and Hoki roe (18.6%). Phosphatidylcholine was the main phospholipid in Gemfish roe (34.6%) and Hoki roe (28.7%). Alcalase achieved the most extensive hydrolysis, and its hydrolysate displayed the highest 2,2-dipheny1-1-picrylhydrazyl (DPPH)˙ and 2,2'-azino-bis(3-ethylbenzothiazoline-6-sulfonic acid) (ABTS) radical scavenging activities and ferric reducing antioxidant power (FRAP). The combination of defatting and freeze-drying treatments reduced DPPH˙ scavenging activity (by 38%), ABTS˙ scavenging activity (by 40%) and ferric (Fe3+) reducing power by18% (p < 0.05). These findings indicate that pre-processing treatments of delipidation and freeze-drying could negatively impact the effectiveness of enzymatic hydrolysis in extracting valuable compounds from low grade roe.

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Fenbendazole is an antiparasitic drug widely used in veterinary medicine to treat parasitic infections caused in animals like cattle, horses, sheep, and dogs. Recently, it has been repositioned as a potential alternative for cancer treatment. However, it is a highly hydrophobic molecule (0.9 ug/mL), which can compromise its dissolution rate and absorption. Thus, this work aimed to apply a nanotechnological approach to improve drug solubility and dissolution performance. Fenbendazole nanoparticles stabilized by different poloxamers were obtained by lyophilization without cryoprotectants. The behavior of the drug in the solid state was analyzed by X-ray diffractometry, differential scanning calorimetry, and infrared spectroscopy. The nanosystems were also evaluated for solubility and dissolution rate. A long-term stability evaluation was performed for three years at room temperature. The yields of the lyophilization ranged between 75 and 81% for each lot. The nanoparticles showed a submicron size (< 340 nm) and a low polydispersity depending on the stabilizer. The physicochemical properties of the prepared systems indicated a remarkable amorphization of the drug, which influenced its solubility and dissolution performance. The drug dissolution from both the fresh and aged nanosystems was significantly higher than that of the raw drug. In particular, nanoparticles prepared with poloxamer 407 showed no significant modifications in their particle size in three years of storage. Physical stability studies indicated that the obtained systems prepared with P188, P237, and P407 suffered certain recrystallization during long storage at 25 °C. These findings confirm that selected poloxamers exhibited an important effect in formulating fenbendazole nanosystems with improved dissolution.

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High valence multi transition metal hydroxides are greatly enriched with OER redox active sites due to strong synergy of heteroatomic nuclei. The efficiency of these redox active sites could be efficiently improved by coupling with highly conductive substrate. The advanced three-dimensional (3D) architecture and hydrophilic terminal functionalities of MXene (MX) considerably enhance the maximum utilization rate of anchored redox active sites by triggering the direct growth of these at MX substrate. Here-in, the freeze-dried 3D network of crumpled Vanadium-Carbide (V2C) MX sheets regulates the crystallization of in-situ grown NiFeCr multi transition metal hydroxides on MX scaffold through co-precipitation process. The XPS results suggest a synergistic chemical interaction of 3D MX scaffold with NiFeCr that modifies the electronic structure of the composite ensuring reduced charge transfer resistance. Besides, as found in FESEM morphological investigation, the well-dispersed NiFeCr multi-transition metal hydroxides are immobilized on open pores like structure of V2C-MX facilitate thoroughly accessible active sites. As a result, the NiFeCr@3D V2C-MX composite has shown an excellent electrocatalytic activity with an overpotential of 410 mV at a current density of 200 mA cm-2, Tafel slope of 100 mV dec in 1M KOH. Besides, the significant interaction between metallic centers and MXene support prevent detachment or agglomeration of active centers providing maximum interaction with the electrolytic ions, quick ionic OH- transportation, speedy and stable electron transfer channels thus ensure the long-term stability of NV-5MX during 53 h continuous operation of OER. Furthermore, we have utilized a more accurate value of half-cell standard reduction potential of the Hg/HgO electrode in the Nernst equation to represent all test voltages and to determine the overpotential values. In essence, this study features a facile approach for the confined growth of multi transition metal hydroxides in the presence of morphologically unique 3D crumpled V2C MXene architectures. Consequently, the increased OER reaction kinetics and improved stability of the synthesized composites are potentially due to synergistic interplay between well dispersed active sites and the conductive substrate.

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The n-type semiconductor SnO2 with a wide band gap (3.6 eV) is massively used in gas-sensitive materials, but pure SnO2 still suffers from a high operating temperature, low response, and tardy responding speed. To solve these problems, we prepared small-sized pure SnO2 using hydrothermal and freeze-drying methods (SnO2-FD) and compared it with SnO2 prepared using a normal drying method (SnO2-AD). The sensor of SnO2-FD had an ultra-high sensitivity to NO2 at 100 °C with excellent selectivity and humidity stability. The outstanding gas sensing properties are attributed to the modulation of energy band structure and the increased carrier concentration, making it more accessible for electron exchange with NO2. The excellent gas sensing properties of SnO2-FD indicate its tremendous potential as a NO2 sensor.

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Extracellular vesicles (EVs) have emerged as a promising drug delivery system. Connectosomes are a specialized type of EVs that contain connexins in their membranes. Connexin is a surface transmembrane protein that forms connexin hemichannels. When a connexin hemichannel on a connectosome docks with another connexin hemichannel of a target cell, they form a gap junction that allows direct intracellular delivery of therapeutic cargos from within the connectosome to the cytoplasm of the recipient cell. In the present study, we tested the feasibility of converting connectosomes into dry powders by (thin-film) freeze-drying to enable their potential storage in temperatures higher than the recommended -80 °C, while maintaining their activity. Connectosomes were isolated from a genetically engineered HeLa cell line that overexpressing connexin-43 subunit protein tagged with red fluorescence protein. To facilitate the testing of the function of the connectosomes, they were loaded with calcein green dye. Calcein green-loaded connectosomes were thin-film freeze-dried with trehalose alone or trehalose and a polyvinylpyrrolidone polymer as lyoprotectant(s) to produce amorphous powders with high glass transition temperatures (>100 °C). Thin-film freeze-drying did not significantly change the morphology and structure of the connectosomes, nor their particle size distribution. Based on data from confocal microscopy, flow cytometry, and fluorescence spectrometry, the connexin hemichannels in the connectosomes reconstituted from the thin-film freeze-dried powder remained functional, allowing the passage of calcein green through the hemichannels and the release of the calcein green from the connectosomes when the channels were opened by chelating calcium in the reconstituted medium. The function of connectosomes was assessed after one month storage at different temperatures. The connexin hemichannels in connectosomes in liquid lost their function when stored at -19.5 ± 2.2 °C or 6.0 ± 0.5 °C for a month, while those in dry powder form remained functional under the same storage conditions. Finally, using doxorubicin-loaded connectosomes, we showed that the connectosomes reconstituted from thin-film freeze-dried powder remained pharmacologically active. These findings demonstrate that (thin-film) freeze-drying represents a viable method to prepare stable and functional powders of EVs that contain connexins in their membranes.

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Active pharmaceutical ingredient (API) embedded dry powder for inhalation (AeDPI) shows higher drug loading and delivery dose for directly treating various lung infections. Inspired by the dandelion, we propose a novel kind of AeDPI microparticle structure fabricated by spray freeze drying technology, which would potentially enhance the alveoli deposition efficiency. When inhaling, such microparticles are expected to be easily broken-up into fragments containing API that acts as 'seed' and could be delivered to alveoli aided by the low density 'pappus' composed of excipient. Herein, itraconazole (ITZ), a first-line drug for treating pulmonary aspergillosis, was selected as model API. TPGS, an amphiphilic surfactant, was used to achieve stable primary ITZ nanocrystal (INc) suspensions for spray freeze drying. A series of microparticles were prepared, and the dandelion-like structure was successfully achieved. The effects of feed liquid compositions and freezing parameters on the microparticle size, morphology, surface energy, crystal properties and in vitro aerosol performance were systematically investigated. The optimal sample (SF(-50)D-INc7Leu3-2) in one-way experiment showed the highest fine particle fraction of ∼ 68.96 % and extra fine particle fraction of ∼ 36.87 %, equivalently ∼ 4.60 mg and ∼ 2.46 mg could reach the lung and alveoli, respectively, when inhaling 10 mg dry powders. The response surface methodology (RSM) analysis provided the optimized design space for fabricating microparticles with higher deep lung deposition performance. This study demonstrates the advantages of AeDPI microparticle with dandelion-like structure on promoting the delivery efficiency of high-dose drug to the deep lung.

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The pharmaceutical industry is progressing towards more continuous manufacturing techniques. To dry biopharmaceuticals, continuous freeze drying has several advantages on manufacturing and process analytical control compared to batch freeze-drying, including better visual inspection potential. Visual inspection of every freeze-dried product is a key quality assessment after the lyophilization process to ensure that freeze-dried products are free from foreign particles and defects. This quality assessment is labor-intensive for operators who need to assess thousands of samples for an extensive amount of time leading to certain drawbacks. Applying Artificial Intelligence, specifically computer vision, on high-resolution images from every freeze-dried product can quantitatively and qualitatively outperform human visual inspection. For this study, continuously freeze-dried samples were prepared based on a real-world pharmaceutical product using manually induced particles of different sizes and subsequently imaged using a tailor-made setup to develop an image dataset (with particle sizes from 50µm to 1 mm) used to train multiple object detection models. You Only Look Once version 7 (YOLOv7) outperforms human inspection by a large margin, obtaining particle detection precision of up to 88.9% while controlling the recall at 81.2%, thus detecting most of the object present in the images, with an inference time of less than 1 s per vial.

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New drying technologies for biologicals have recently been developed to accelerate the time-consuming batch freeze-drying (BFD) process. Among others, microwave-assisted freeze-drying (MFD) has been suggested as a faster and more effective drying technology. In this study, MFD cycles with the microwave radiation switched on and off were performed to assess the contribution of the microwave radiation to drying acceleration. It was found that thermal radiation emitted by the drying chamber walls was predominantly accelerating the drying of monodose placebos rather than microwave radiation. The combination of ultra-low chamber pressure, high thermal heat transfer and a short primary-to-secondary phase transition reduces drying times by more than 80 % compared to conventional BFD. In a second step, a design of experiment approach was used to assess the effect of thermal radiation versus microwave radiation and their combination, together with dosage properties such as fill volume and excipient concentration upon drying rate. The outcome showed the importance of high fill volume and high excipient concentration for an effective microwave contribution to the drying rate. Nevertheless, the drying acceleration for small pharmaceutical dosages with restricted solutes was mainly driven by thermal radiation rather than 2.45 GHz microwave radiation. The inability of ice to convert microwave energy into heat hampers the potential use of microwave freeze-drying for single-dose vaccines.

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A biomass CS/CNTs@MTMS (MCCS) aerogel with both aligned channel network, superhydrophobicity, and photothermal conversion ability was prepared by a green and facile strategy of directed freeze-drying and chemical vapor deposition using chitosan (CS), carbon nanotubes (CNTs), and methyltrimethoxysilane (MTMS) as the building materials. Capacity to adsorb a large variety of oils and organic solvents, with an adsorption capacity of up to 34-83 g/g. After 10 cycles, the adsorption capacity of MCCS remained at 94 % of the initial capacity, providing excellent reusability. In addition, due to its unique network of aligned channels, the MCCS can continuously separate oil and water, making it a sustainable oil-water separator. More interestingly, the MCCS aerogel has excellent photothermal conversion capabilities, and it was utilized to evaporate oil collected during the oil-water separation process using solar energy. This work provides an opportunity to design novel self-cleaning photothermally driven oil-water separation biomass materials with superhydrophobicity-strong lipophilicity.

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Over the past decade, continuous spin freeze-drying technology has emerged as a promising alternative to conventional batch freeze-drying, effectively addressing many of the latter's inherent disadvantages. Much of the focus during this period has been on controlling and optimizing the primary drying phase of this process. However, optimizing the secondary drying step is equally critical for the overall efficiency of the process. The primary aim of this study was to develop a comprehensive semi-mechanistic model for the secondary drying phase in continuous spin freeze-drying, accounting for the effects of process settings such as freezing rate and product temperature on desorption kinetics. Additionally, the study aimed to address discrepancies between conventional desorption models, typically applied in batch freeze-drying, and the observed data in this research. To achieve this, a residual moisture-dependent activation energy was introduced to improve the accuracy of the desorption model. Using NIR spectroscopy and IR-thermography, unknown model parameters could reliably be estimated using a simple and fast procedure. The calibrated model successfully predicted the final moisture content with an accuracy within 0.11% of the measured value under previously untested process conditions. Ultimately, the proposed semi-mechanistic model demonstrated its reliability in predicting the impact of new process conditions on both product temperature and residual moisture over time, enabling the development of a practical design space.

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