Dry Microcapsules

Dry microcapsules transform liquid raw materials into stable, easily integrable powders

Unlike aqueous suspension microcapsules, this form undergoes a careful drying process, transforming liquid raw materials into a fine powder. These microcapsules are suitable for numerous industrial applications, thanks to their unique properties.
The size of the microcapsules can range from 50 to 1,500 µm, depending on the characteristics of the microencapsulated raw material.
Dry microcapsules are produced through coacervation — the same technology behind slurry microcapsules — and are subsequently subjected to a drying process, transforming the aqueous suspension into a fine, stable powder.

Production process

The production of dry microcapsules takes place in two distinct and sequential stages, which transform the lipophilic raw material into a fine, stable powder.

Microencapsulation by coacervation
The lipophilic substance to be encapsulated is dispersed in an aqueous solution containing gelatin as the wall polymer. By modifying the process conditions, the polymers coacervate and deposit around the droplets of the active substance, forming a continuous membrane. The resulting structure is of the core-shell type: an active core protected by a gelatin shell.
Drying and sieving
The microcapsules are transferred to a dryer where a controlled flow of hot air removes the aqueous phase, transforming the suspension into a powder. The process ensures homogeneous drying without degrading the microcapsules or the active ingredient. The powder is subsequently sieved to select the particle size fractions within the required size range.

Technical parameters

Below are the main technical parameters of IPS dry microcapsules, useful for assessing their compatibility with your production process:

Parameter	Value / notes
Microcapsule size	50 – 1,500 µm (selectable by sieving)
Average active content	80 – 85%
Residual moisture	< 10%
Wall material (shell)	Gelatin
Drying process	Fluid bed drying
Particle size control	Post-drying sieving

For specific requirements or to assess compatibility with your production process, please contact the IPS team.

Dry Microcapsules vs. Slurry Microcapsules: WHEN TO CHOOSE WHICH

The choice between dry and slurry microcapsules depends primarily on the customer’s production process and the type of final formulation.

	Dry Microcapsules	Slurry Microcapsules
Physical form	Fine powder	Aqueous suspension
Process integration	Ideal for solid formulations and dry processes	Ideal for aqueous processes: impregnation, coating, padding
Dosage	Easy gravimetric dosing (weighing)	Volumetric dosing of the suspension
Compatibility	Dry mixing processes, powders, patches, transdermal patches	Textile, paper, tissue, non-woven, industrial personal care
Microcapsule size	50 – 1.500 µm	20 – 500 µm
Average active content	80 – 85% in peso	Variable depending on the formulation

Technical specifications

Dry microcapsules are distinguished by four key technical characteristics that ensure their reliability and functionality in every application:

Stability
Good stability is crucial to ensure that the microcapsules remain uniformly dispersed without aggregating.
Content protection
Microcapsules protect the encapsulated materials from degradation or premature reactions, ensuring a longer shelf life.
Trigger-activated functionality
Microcapsules can be designed to respond to specific external stimuli, such as changes in pH, pressure or others.
Ease of integration
The powder form integrates easily into dry production processes, with no need to manage an aqueous phase.

Applications

The currently most established application for IPS dry microcapsules is the production of functional patches. The powder form integrates seamlessly into the manufacturing processes of these products, enabling precise dosing and uniform distribution of the active ingredient.

Potential application developments

La forma secca delle microcapsule, con il suo elevato contenuto attivo (80–85%) e la facilità di integrazione in processi a secco, si presta potenzialmente a una vasta gamma di applicazioni industriali. Per valutare la fattibilità tecnica di nuove applicazioni, IPS offre un servizio di sviluppo e prototipazione dedicato.

IPS Dry Microcapsules Application Examples

Examples of already developed products and achievable solutions using IPS Dry Microcapsules. These cards bring together the application cases and concepts that use this process. Do you have a specific requirement or a new project in mind? Contact IPS for more information: we will assess the most suitable solution together.

Case Study

Development of scented patches with core-shell microcapsules

Integration of slurry and dry microcapsules into the adhesive material to achieve...

FAQ — Dry Microcapsules

Frequently asked questions about powder microcapsules for industrial applications

What are dry microcapsules?

Dry microcapsules are produced by coacervation and subsequently dried, transforming liquid substances into a fine, stable powder. The result is a solid product that is easy to dose, store and integrate into dry formulations and production processes.

How are dry microcapsules produced?

Production takes place in two stages: first microencapsulation by coacervation (the active substance is coated by a gelatin membrane), then fluid bed drying (a controlled flow of hot air removes the aqueous phase, transforming the suspension into a powder). The powder is finally subjected to sieving to select the particle size fraction within the required size range.

What are the main technical parameters of IPS dry microcapsules?

The main parameters are: size in variable ranges within the 50–1,500 µm span (selectable by sieving), average active content 80–85%, residual moisture < 10%, wall material in gelatin, fluid bed drying with particle size control by sieving.

What is the difference between dry microcapsules and slurry microcapsules?

The main difference is the physical form: dry microcapsules are a powder, while slurry microcapsules are an aqueous suspension. Dry microcapsules integrate into dry processes (patches, powder blending), while slurry microcapsules integrate into aqueous processes (textile impregnation, coating, padding). Dry microcapsules have a higher active content (80–85%) and sizes up to 1,500 µm, while slurry microcapsules reach up to 500 µm.

In which applications are IPS dry microcapsules currently used?

The currently most established application is the production of patches and transdermal patches, in particular anti-mosquito patches with microencapsulated essential oils (citronella, eucalyptus, lavender or others). The powder form integrates seamlessly into the manufacturing processes of these products, enabling precise dosing and uniform distribution of the active ingredient.

What is the wall material (shell) of the dry microcapsules?

The wall material used is gelatin.

How should the 80–85% active content be interpreted?

This indicates that 80–85% of the total powder weight consists of the microencapsulated active ingredient, while the remaining 15–20% is represented by the gelatin membrane. This is a very high value compared to many other forms of microencapsulation, which makes IPS dry microcapsules particularly efficient in terms of dosage.

How should dry microcapsule powder be stored?

Dry microcapsule powder does not require any special storage conditions: it is sufficient to store it in a cool and dry environment, away from sources of heat and moisture.

Is it possible to customise the microcapsule size?

Yes, the microcapsule size is variable within the range of 50–1,500 µm through the post-drying sieving process. The optimal size depends on the characteristics of the microencapsulated raw material, the final application and the customer's production process.

Which active ingredients can be microencapsulated in dry form?

IPS has experience in dry microencapsulation of essential oils and fragrances (citronella, eucalyptus, lavender and others). For raw materials not included in the standard list, a feasibility assessment can be requested. The coacervation process is suitable for lipophilic substances.

How can I request samples or initiate a technical evaluation?

To request samples or initiate an evaluation, you can fill in the contact form or contact the IPS team directly. IPS follows a structured process → Find out more:

Analysis of raw materials
Definition of the microencapsulation strategy
Experimentation and prototyping
Optimisation and industrialisation

We develop microencapsulation projects through a structured process:

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