The continuous fabrication via membrane
emulsification of stable
microcapsules using renewable, biodegradable biopolymer wall materials
keratin and chitosan is reported here for the first time. Microcapsule
formation was based on opposite charge interactions between keratin
and chitosan, which formed polyelectrolyte complexes when solutions
were mixed at pH 5.5. Interfacial complexation was induced by transfer
of keratin-stabilized primary emulsion droplets to chitosan solution,
where the deposition of chitosan around droplets formed a core–shell
structure. Capsule formation was demonstrated both in batch and continuous
systems, with the latter showing a productivity up to 4.5 million
capsules per minute. Keratin–chitosan microcapsules (in the
30–120 μm range) released less encapsulated nile red
than the keratin-only emulsion, whereas microcapsules cross-linked
with glutaraldehyde were stable for at least 6 months, and a greater
amount of cross-linker was associated with enhanced dye release under
the application of force due to increased shell brittleness. In light
of recent bans involving microplastics in cosmetics, applications
may be found in skin-pH formulas for the protection of oils or oil-soluble
compounds, with a possible mechanical rupture release mechanism (e.g.,
rubbing on skin).