Microplastic-Free Microcapsules Using Supramolecular Self-Assembly of Bis-Urea Molecules at an Emulsion Interface

Encapsulation technology is well established for entrapping active ingredients within an outer shell for their protection and controlled release. However, many solutions employed industrially use nondegradable cross-linked synthetic polymers for shell formation. To curb rising microplastic pollution, regulatory policies are forcing industries to substitute the use of such intentionally added microplastics with environmentally friendly alternatives. This work demonstrates a one-pot process to make microplastic-free microcapsules using supramolecular self-assembly of bis-ureas. Molecular bis-urea species generated <i>in-situ</i> spontaneously self-assemble at the interface of an oil-in-water emulsion via hydrogen bonding to form a shell held together by noncovalent bonds. In addition, Laponite nanodiscs were introduced in the formulation to restrict aggregation observed during the self-assembly and to reduce the porosity of the shell, leading to well-dispersed microcapsules (mean Sauter diameter <i>d</i> [3,2] ∼ 5 μm) with high encapsulation efficiency (∼99%). Accelerated release tests revealed an increase in characteristic release time of the active by more than an order of magnitude after encapsulation. The mechanical strength parameters of these capsules were comparable to some of the commercial, nondegradable melamine-formaldehyde microcapsules. With mild operating conditions in an aqueous environment, this technology has real potential to offer an industrially viable method for producing microplastic-free microcapsules.