Review of the technological advances for the preparation of colloidal dispersions at high production throughput using microporous membrane systems

Abstract

The membrane emulsification (ME) method is a highly promising technology that utilizes synthetic microporous membranes to produce high-quality, droplet-size controlled dispersions and colloidal particles at low shear stress and low energy input. This technology has enabled the preparation of microspheres, microcarriers, microcapsules, polymers, and gel microbeads with tunable properties, which find extensive applications in drug delivery systems and the formulation of novel products in the cosmetics, chemical, pharmaceutical, and food industries. Despite its potential for use in various processes, the adoption of ME technology has been limited by its low production throughput. To overcome this limitation, numerous approaches have been developed over the years, including new ME methodologies, fabrication of new membranes, use of new additives and formulations, and optimization of process conditions. This review comprehensively explores these approaches and highlights the major process parameters that control production throughput and their relationship to membrane and ingredient properties. While a single technique may not be universally applicable in all fields, utilizing multiple strategies can significantly enhance the production throughput of the ME method. A thorough understanding of the ingredients’ nature, final product requirements, and process limitations can aid in determining the most suitable strategies to employ in different fields of application.