A recent push for surfactant-free
products driven by environmental
awareness has propelled the use of bio-based materials in place of
petroleum-derived components. However, both the formulation and processing
need to be considered for scale-up feasibility and environmental sustainability.
This work investigated the drying of corn oil-in-water emulsions stabilized
by cellulose nanocrystals (CNCs), methyl cellulose (MC), and tannic
acid via freeze drying, spray freeze drying, and spray drying. All
three techniques produced oil powders with low moisture content and
high encapsulated oil content (>90%). The oil powders could be
redispersed
in water by hand shaking to reform the original emulsion and could
be stored dry for weeks without oil leakage (in the fridge). The release
of oil from the powders on hydrophobic substrates (at room temperature)
was controlled by changing the CNC and MC stabilizer content; the
spray freeze dried samples were the most tunable. The three drying
techniques imparted different surface morphologies that were linked
to powder redispersibility and oil release properties. The lack of
freezing (and associated ice crystal growth) in spray drying minimized
oil droplet agglomeration, and it was the fastest, most scalable,
and least energy-intensive drying technique of the three, but it was
also the most sensitive to emulsion concentration and susceptible
to instabilities associated with high temperature and shear stress.
It was demonstrated that essential oils with a range of interfacial
tensions and volatilities (e.g., jojoba, lavender, tea tree oil) could
also be encapsulated in spray dried oil powders. This general encapsulation
strategy can be tailored based on the drying technique selected, uses
plant-based industrially-produced feedstocks, works with commercially
relevant oils, and will hopefully contribute to the development of
sustainable emulsions and oil powders for food, pharmaceutical, agricultural,
and cosmetic applications.