Microfluidic encapsulation of probiotics presents significant engineering challenges due to the sensitivity of live bacterial cells to processing conditions. Current systems operate with flow rates between 30-200 μL/min through channels 50-500 μm in diameter, where shear forces must be precisely controlled to prevent cellular damage. Temperature gradients during encapsulation must remain within ±2°C of optimal conditions, as thermal stress significantly impacts probiotic viability rates, often reducing survival by 25-40% when improperly managed.

The fundamental challenge lies in developing encapsulation technologies that protect probiotic viability through manufacturing processes while ensuring targeted release at specific gastrointestinal sites.

This page brings together solutions from recent research—including surface acoustic wave atomization for nano-scale capsule formation, triple-layer coating systems with vegetable wax barriers, pH-sensitive alginate matrices with controlled particle sizes of 30-35 μm, and single-vessel bioreactors with sequential culturing zones. These and other approaches demonstrate how microfluidic technologies are revolutionizing probiotic delivery by enhancing stability during processing, storage, and gastrointestinal transit.

1. Solid Feed Additive with Freeze-Dried Megasphaera Elsdenii Bacteria and Encapsulation for Enhanced Stability

AXIOTA US INC, KANSAS STATE UNIVERSITY RESEARCH FOUNDATION, 2025

Solid feed additive, composition, and method to improve animal growth and health by administering freeze-dried Megasphaera elsdenii bacteria to animals like poultry and equines. The M. elsdenii cells are produced by culturing the bacteria, harvesting them, freezing, and freeze-drying under anaerobic conditions. This allows long-term storage without refrigeration. Administering the freeze-dried cells improves feed intake, growth rate, conversion, carcass gain, egg production, bone mineralization, etc. It also prevents lactic acid buildup and reduces opportunistic microbe growth in the gut. Encapsulating the cells further enhances stability.

2. Microbial Culture Encapsulation with Triple Layer Coating Including Vegetable Wax Admixture

CHR HANSEN AS, 2025

Microencapsulated microbial cultures with enhanced survivability under harsh conditions, such as high temperature, high acidity, and high water activity. The cultures comprise a core material of microbial cells encapsulated by three coating layers: a first layer of plant-based polymer, a second layer of a specific vegetable wax admixture, and a third layer of plant-based polymer. The vegetable wax admixture, comprising a medium melting point wax and a high melting point wax, provides thermal insulation and protection against environmental stressors.

3. Method for Forming Probiotic-Embedded Microcapsules with Controlled Particle Size and pH-Sensitive Release

NATIONAL INSTITUTE FOR NUTRITION AND HEALTH CHINESE CENTER FOR DISEASE CONTROL AND PREVENTION, 2025

A method for preparing probiotic-loaded microcapsules that maintain the activity of the embedded probiotics and easily release them in the intestines. The method involves mixing a sodium alginate solution with a probiotic suspension, then spraying a calcium salt solution through a nozzle to form microcapsules. The microcapsules have a controlled particle size of 30-35 μm and exhibit pH-sensitive release characteristics, allowing them to disintegrate in the weak acid environment of the intestines and release the embedded probiotics.

4. Synthetic Bacterial Microcompartment Comprising CcmK2 Shell Protein with Encapsulation and Enzymatic Activity Capabilities

THE REGENTS OF THE UNIVERSITY OF MICHIGAN, 2025

A single-component synthetic bacterial microcompartment (BMC) comprising a single shell protein subunit, CcmK2, that can encapsulate agents and exhibit enzymatic activity. The CcmK2 BMC can be assembled in vitro through controlled pH and salt conditions, and its size and properties can be modulated. The BMC can encapsulate a wide range of agents, including enzymes, nanomaterials, and organic/inorganic compounds, and can be used for various applications such as biocatalysis, diagnostics, and bioremediation.

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5. Microcapsules with Methacrylic Acid-Alginic Acid Copolymer Shell Encapsulating Probiotic Strains

University of Bari Aldo Moro, 2025

Microcapsules containing probiotic strains that can withstand the stresses of food preparation and storage, including high temperatures, pH variations, and digestive enzymes. The microcapsules incorporate a polymer shell that protects the probiotic microorganisms while maintaining their viability. The polymer shell is comprised of a copolymer of methacrylic acid and alginic acid, with a prebiotic component. This formulation enables the probiotics to colonize the intestinal environment without compromising their activity, making it ideal for food products that require probiotic preservation during processing.

6. Nano-Scale Probiotic Microcapsules via Low-Temperature Ultrasonic Atomization with Surface Acoustic Wave Atomizer

SHENZHEN INSTITUTES OF ADVANCED TECHNOLOGY, 2024

Nano-scale probiotic microcapsules prepared by low-temperature ultrasonic atomization technology, comprising a method of injecting a low-temperature treated probiotic suspension into a surface acoustic wave atomizer to produce nano-droplets encapsulating the probiotics. The microcapsules exhibit improved bioavailability, stability, and targeting properties, enabling precise delivery of probiotics to the gastrointestinal tract and lungs for enhanced therapeutic effects.

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7. Heat-Treated Beverage with Fluidized Bed Encapsulated Probiotic Microparticles

ANABIO TECH LTD, 2024

Shelf-stable, heat-treated beverage containing encapsulated probiotics that can be stored at ambient temperatures for extended periods without spoilage. The beverage contains microparticles with live probiotics encapsulated within. The microparticles are made by coating a core of sub-microparticles containing the probiotics with denatured protein using a fluidized bed process. This prevents leakage and degradation of the probiotics during heat treatment and storage. The encapsulated probiotics survive UHT processing and maintain viability for 24 months at room temperature.

8. Effect of Encapsulation of <i>Lactobacillus casei</i> in Alginate–Tapioca Flour Microspheres Coated with Different Biopolymers on the Viability of Probiotic Bacteria

Anna Łętocha, Alicja Michalczyk, Małgorzata Miastkowska - American Chemical Society (ACS), 2024

To realize the health benefits of probiotic bacteria, they must withstand processing and storage conditions and remain viable after use. The encapsulation of these probiotics in the form of microspheres containing tapioca flour as a prebiotic and vehicle component in their structure or shell affords symbiotic effects that improve the survival of probiotics under unfavorable conditions. Microencapsulation is one such method that has proven to be effective in protecting probiotics from adverse conditions while maintaining their viability and functionality. The aim of the work was to obtain high-quality microspheres that can act as carriers of

9. Capsule with Multi-Nutrient Microspheres and Hydrogel Matrix Featuring Enteric Coating and Laser-Punched Shell

SHANDONG RIENTECH MEDICAL TECHNOLOGY CO LTD, 2024

A diet-reducing capsule containing multi-nutrient microspheres for weight loss and nutritional supplementation. The capsule comprises microspheres encapsulating probiotics, prebiotics, vitamins, and minerals, which are protected from gastric acid and bile salts by an enteric coating. The microspheres are attached to a hydrogel matrix that provides a stable environment for nutrient release. The capsule shell is modified with laser-punched holes to accelerate gastric juice dissolution and timed nutrient release. The capsule promotes satiety, supports gut health, and provides essential nutrients for weight management.

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10. Microfluidic Mixing Method for Nucleic Acid Encapsulation in Liposomes

VIROGIN BIOTECH LTD, 2024

A method for preparing nucleic acid-encapsulation complexes using microfluidic mixing, where nucleic acids are introduced into empty encapsulation bodies such as liposomes through a microfluidic chip. The method enables direct administration of the complexes without the need for organic solvent removal or cold chain storage, and achieves comparable quality to traditional methods.

11. Microfluidic Strategies for Encapsulation, Protection, and Controlled Delivery of Probiotics

Kuiyou Wang, Kexin Huang, Li Wang - American Chemical Society (ACS), 2024

Probiotics are indispensable for maintaining the structure of gut microbiota and promoting human health, yet their survivability is frequently compromised by environmental stressors such as temperature fluctuations, pH variations, and mechanical agitation. In response to these challenges, microfluidic technology emerges as a promising avenue. This comprehensive review delves into the utilization of microfluidic technology for the encapsulation and delivery of probiotics within the gastrointestinal tract, with a focus on mitigating obstacles associated with probiotic viability. Initially, it elucidates the design and application of microfluidic devices, providing a precise platform for probiotic encapsulation. Moreover, it scrutinizes the utilization of carriers fabricated through microfluidic devices, including emulsions, microspheres, gels, and nanofibers, with the intent of bolstering probiotic stability. Subsequently, the review assesses the efficacy of encapsulation methodologies through in vitro gastrointestinal simulations and in vivo experimentation, underscoring the potential... Read More

12. Single Vessel Bioreactor with Sequential Culturing Zones and Porous Membrane Separation

CITY UNIVERSITY OF HONG KONG, 2024

A single vessel bioreactor with multiple culturing zones arranged sequentially to provide gradients in pH and oxygen levels for simultaneously culturing multiple microbial strains in a single bioreactor vessel. The gradients mimic the gut environment for producing microbiome-based products like probiotics. The bioreactor has zones separated by porous membranes that prevent strain migration but allow communication. Each zone has a hydrogel with different porosity, chemistry, water retention, and stiffness to create the gradients. This enables culturing strains adapted to specific pH and oxygen levels simultaneously in a single reactor.

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13. Microencapsulation Structure with Oil and Lipid Layers for Sensitive Material Protection

MELLO APS, 2024

Microencapsulating sensitive materials like probiotics to safely and efficiently deliver them to target locations like the gut. The encapsulation involves a core material like probiotics surrounded by an oil layer and then a solidifying lipid layer. The core is suspended in oil, then contact with molten lipid to form a solid shell. This provides a stable, tolerant microcapsule for delivering sensitive materials like probiotics through harsh conditions like stomach acid and moisture. The capsules have high viability and retention of the core material after storage and distribution.

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14. Encapsulation of Probiotics within Double/Multiple Layer Beads/Carriers: A Concise Review

Sofia Agriopoulou, Slim Smaoui, Moufida Chaari - MDPI AG, 2024

An increased demand for natural products nowadays most specifically probiotics (PROs) is evident since it comes in conjunction with beneficial health effects for consumers. In this regard, it is well known that encapsulation could positively affect the PROs' viability throughout food manufacturing and long-term storage. This paper aims to analyze and review various double/multilayer strategies for encapsulation of PROs. Double-layer encapsulation of PROs by electrohydrodynamic atomization or electrospraying technology has been reported along with layer-by-layer assembly and water-in-oil-in-water (W

15. Microencapsulated Microbial Cultures with Non-Homogeneous Coacervate Matrix Containing Carbohydrates, Proteins, and Antioxidants

CHR HANSEN AS, 2024

Microencapsulated microbial cultures with enhanced storage stability at elevated temperatures, comprising a microbial culture entrapped in a coacervate comprising a non-homogeneous encapsulation matrix with a high ratio of matrix material to core material, wherein the matrix material includes carbohydrates, proteins, and antioxidants. The microencapsulated cultures exhibit preserved viability over extended periods of storage at temperatures up to 37°C, enabling applications in products where refrigerated storage is not feasible.

16. The encapsulation strategy to improve the survival of probiotics for food application: From rough multicellular to single-cell surface engineering and microbial mediation

Yongkai Yuan, Yin Ming, Qixiao Zhai - Informa UK Limited, 2024

The application of probiotics is limited by the loss of survival due to food processing, storage, and gastrointestinal tract. Encapsulation is a key technology for overcoming these challenges. The review focuses on the latest progress in probiotic encapsulation since 2020, especially precision engineering on microbial surfaces and microbial-mediated role. Currently, the encapsulation materials include polysaccharides and proteins, followed by lipids, which is a traditional mainstream trend, while novel plant extracts and polyphenols are on the rise. Other natural materials and processing by-products are also involved. The encapsulation types are divided into rough multicellular encapsulation, precise single-cell encapsulation, and microbial-mediated encapsulation. Recent emerging techniques include cryomilling, 3D printing, spray-drying with a three-fluid coaxial nozzle, and microfluidic. Encapsulated probiotics applied in food is an upward trend in which "classic probiotic foods" (yogurt, cheese, butter, chocolate, etc.) are dominated, supplemented by "novel probiotic foods" (tea, p... Read More

17. Viability of Free and Alginate–Carrageenan Gum Coated <i>Lactobacillus acidophilus</i> and <i>Lacticaseibacillus casei</i> in Functional Cottage Cheese

Muhammad Saeed, Rehana Khanam, Hammad Hafeez - American Chemical Society (ACS), 2024

The survivability of encapsulated and nonencapsulated probiotics consisting of

18. The Microcapsule Based on the Maillard Reaction Product from Spray Drying to Deliver Probiotics

Miaoshu Wang - Warwick Evans Publishing, 2024

The physical fitness improving capacity of probiotics has been proved to be valid but easy to degrade when exposed to the environment of processing, storage, and human gastrointestinal tract. A series of research have shown that the microcapsule embedding technology or coating technology with certain Maillard Reaction products (MRPs) as the wall material has the potential to improve the delivery condition, protect the probiotic supplements and helping the ideal expressing of probiotics in the gastrointestinal environment. This article explores the tactics that enforce microencapsulation of probiotics with microcapsule, which uses MRPs as wall material. The action mechanism of probiotics in microcapsule and the potential embedding techniques to develop the probiotic delivery systems will also be covered in this essay. However, the action mechanism of microcapsule-probiotic system taken place in vivo tract is still hot topic considering the studies performed through vitro strategy are not forcible enough considering the exogenous factors that cannot be tested.

19. Method for Producing Core-Shell Microparticles via Bacterial Cellulose-Polyhydroxyalkanoate Grafting and Coaxial Electrospraying

CONSORCIO CENTRO DE INVESTIG BIOMEDICA EN RED, 2024

A method for producing core-shell microparticles using bacterial cellulose (BC) and polyhydroxyalkanoates (PHAs) for encapsulating bioactive cargos. The method involves grafting PHAs onto BC through an acylation reaction, followed by coaxial electrospraying to form spherical particles with a BC-PHA core and a PHA shell. The particles can be used for controlled release of bioactive substances.

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20. Microfluidic Chip System for Core-Shell Organ Microsphere Formation with Separate Cell Suspension and Oil Phase Channels

D1 MEDICAL TECH SHANGHAI CO LTD, 2024

A microfluidic-based system for preparing core-shell structure in vitro organ microspheres (VOS) with uniform size and controllable composition. The system uses a microfluidic chip with separate channels for shell and core cell suspensions and an oil phase, which merge to form a microsphere fluid flow channel. The shell and core cell suspensions are sheared by the oil phase to form microspheres with a core-shell structure. The system enables high-throughput preparation of VOS with precise control over size, composition, and structure, and can be integrated with detection and sorting systems for quality control.

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21. Chitosan-Fe Coated Synbiotic Microcapsule with Variable Amplitude Depth Profile

22. 3D Bioprinted Structure with Biocompatible Polymer Matrix and Encapsulated Probiotic Cells for Sustained Release

23. Probiotic Surface Film with In Situ Cross-Linked Macromolecules and Metal Ion Complexation

24. Preparation and characterisation of novel casein-gum Arabic composite microcapsules for targeted in vivo delivery of Lactiplantibacillus plantarum A3

25. Microencapsulation with biopolymers—current/next-generation probiotics and impact of FODMAP materials

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