Plant extracts are widely used as natural pesticides, cosmetic ingredients, and in pharmaceutical applications. However, their poor water solubility and stability limit their usability. Lipid nanoparticles (LNPs) offer an effective encapsulation strategy to overcome these challenges. This study demonstrates the encapsulation of three representative substances from these industries: quercetin as a pesticide, irones as a cosmetic ingredient, and nucleic acids for pharmaceutical use. Ultrasonic treatment was used for the encapsulation of quercetin and irones, and a concept for continuous encapsulation in a plug flow reactor was proposed for process intensification. Inline multi-angle light scattering and dynamic light scattering measurements proved effective for real-time monitoring and enabled the replacement of traditional batch measurements. In the pharmaceutical area, mRNA-based therapies require LNP encapsulation to prevent nucleic acid degradation. Plant-based β-sitosterol was used as an alternative helper lipid to cholesterol, resulting in an average particle diameter of 72 nm and an encapsulation efficiency of 91%, comparable to commercial formulations such as the Comirnaty vaccine. Furthermore, a novel process model based on population balances was developed to simulate the entire manufacturing process, from rapid mixing in a T-mixer to particle stabilization via buffer exchange during diafiltration. By applying a quantitative and distinctive model validation workflow, the model was shown to be as accurate and precise as the experimental data, enabling its use as a digital twin for autonomous continuous operation. In summary, this study contributes to reducing the facility footprint and cost of goods through the implementation of continuous processing and model-based control. This approach improves productivity by 20% and reduces process time by a factor of two.
Hengelbrock et al. (Thu,) studied this question.