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

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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.

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Abbreviations

BSA:

Bovine serum albumin

CTAB:

Cetyltrimethylammonium ammonium bromide

EO:

Ethylene oxide

LEO-10:

Dodecyl alcohol-10-glycol ether

PEG:

Polyethylene glycol

PLGA:

Poly (lactic-co-glycolic acid)

PO:

Propylene oxide

SDS:

Sodium dodecyl sulfate

Tween 20:

Polyoxyethylene (20) sorbitan monolaurate

TOMAC:

Tri-n-octyl methylammonium chloride

AAM:

Anodic alumina membranes

PES:

Polyether sulphone membrane

PSF:

Polysulfone membrane

PTFE:

Polytetrafluoroethylene

ZrO2:

Zirconia ceramic membrane

CMC:

Critical micelle concentration

CV:

Coefficient of variation

HLB:

Hydrophilic-lipophilic balance

ME:

Membrane emulsification

SEM:

Scanning electron microscopy

SPG:

Shirasu porous glass

span:

Droplet size distribution

O/W:

Oil-in-water

W/O:

Water-in-oil

\({D}_{i}\) :

Inner membrane diameter, m

\({D}_{{\text{p}}}\) :

Mean pore size, m

\({J}_{{\text{d}}}\) :

Dispersed phase flux, m3/m2s

L :

Membrane length, m

\({L}_{{\text{p}}}\) :

Pore length, m

\({P}_{{\text{cap}}}\) :

Capillary pressure, Pa

Re:

Reynolds number, /

\({R}_{{\text{m}}}\) :

Membrane hydraulic resistance, Pa·s/m2

\({V}_{c}\) :

Velocity continuous phase, m/s

\({V}_{{\text{d}}}\) :

Velocity dispersed phase, m/s

\(\gamma\) :

Interfacial tension, N/m

\({\delta }_{{\text{m}}}\) :

Membrane thickness, m

\(\Delta P\) :

Pressure drop (transmembrane pressure), pa

\({\Delta P}_{t}\) :

Pressure drop due to friction resistance, Pa

ε :

Membrane porosity, /

\({\eta }_{c}\) :

Viscosity continuous phase, Pa·s

\({\eta }_{d}\) :

Viscosity dispersed phase, Pa·s

\(\theta\) :

Contact angle, (°)

\(\lambda\) :

Friction factor, /

ξ :

Mean tortuosity factor, /

\({\rho }_{c}\)Density continuous phase, kg/m:

3

\(\tau\) :

Shear stress, Pa

c:

Continuous phase

d:

Dispersed phase

m:

Membrane

p:

Pore

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Funding

This work was supported by the Korea Institute of Energy Technology Evaluation and Planning (KETEP) grant funded by the Korean Government (MOTIE) (RS-2023–00243201, Global Talent Development project for Advanced SMR Core Computational Analysis Technology Development).

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    Jophous Mugabi & Jae-Ho Jeong

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Mugabi, J., Jeong, JH. Review of the technological advances for the preparation of colloidal dispersions at high production throughput using microporous membrane systems. Colloid Polym Sci 302, 463–485 (2024). https://doi.org/10.1007/s00396-023-05217-8

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