Homogenized formulations containing microcapsules and methods of making and using thereof

1. A method for preparing a homogenized formulation, comprising:

(a) providing a pre-homogenized composition comprising an initial particle size distribution of encapsulated agglomeration microcapsules, wherein each microcapsule comprises an agglomeration of primary microcapsules and a loading substance, each individual primary microcapsule having a primary shell, wherein the loading substance is encapsulated by the primary shell, wherein the agglomeration is encapsulated by an outer shell, wherein the primary shell, the outer shell, or both the primary and outer shells comprise a complex coacervate, and wherein the loading substance comprises a hydrophobic liquid; and

(b) conducting pressure-based homogenization of the pre-homogenized composition at pressures of about 6,000 psi or less to thereby provide a homogenized formulation having a final particle size distribution of the microcapsules which is more narrow than the initial particle size distribution of the microcapsules in the pre-homogenized composition.

2. The method of claim 1 , wherein the pressure-based homogenization of step (b) is conducted by passing the pre-homogenized composition in multiple passes through a multi-stage homogenizer and subjecting the pre-homogenized composition during each of the multiple passes to pressure-based homogenization at a pressure of 6,000 psi or less.

3. The method of claim 1 , wherein the pressure-based homogenization is conducted by a high pressure homogenizer or a very high pressure homogenizer.

4. The method of claim 1 , wherein the pressure-based homogenization is from about 3,000 to about 6,000 psi.

5. The method of claim 1 , further comprising pasteurizing the pre-homogenized composition.

6. The method of claim 1 , further comprising pasteurizing the homogenized formulation.

7. The method of claim 1 , wherein the pre-homogenized composition comprises a comestible, cosmetic, pharmaceutical, nutritional, or health care product.

8. The method of claim 1 , wherein the pre-homogenized composition comprises a dairy product.

9. The method of claim 1 , wherein the pre-homogenized composition comprises an infant formula.

10. The method of claim 1 , wherein the pre-homogenized composition comprises a soy product.

11. The method of claim 1 , wherein the primary shell, the outer shell, or both the primary and outer shells comprise a surfactant, gelatin, polyphosphate, polysaccharide, or a mixture thereof.

12. The method of claim 1 , wherein the primary shell, the outer shell, or both the primary and outer shells comprise gelatin type A, gelatin type B, polyphosphate, gum arabic, alginate, chitosan, carrageenan, pectin, starch, modified starch, alfa-lactalbumin, beta-lactoglobumin, ovalbumin, polysorbiton, maltodextrin, cyclodextrin, cellulose, methyl cellulose, ethyl cellulose, hydropropylmethylcellulose, carboxymethylcellulose, milk protein, whey protein, soy protein, canola protein, albumin, kosher gelatin, non-kosher gelatin, Halal gelatin, non-Halal gelatin, or a mixture thereof.

13. The method of claim 1 , wherein the primary shell, the outer shell, or both the primary and outer shells comprise fish gelatin.

14. The method of claim 1 , wherein the primary shell, the outer shell, or both the primary and outer shells comprise pork gelatin.

15. The method of claim 1 , wherein the primary shell, the outer shell, or both the primary and outer shells comprise a gelatin with a Bloom number of from about 0 to about 50.

16. The method of claim 1 , wherein the primary shell, the outer shell, or both the primary and outer shells comprise a gelatin with a Bloom number of from about 51 to about 300.

17. The method of claim 1 , wherein the primary shell, the outer shell, or both the primary and outer shells comprise a gelatin with a Bloom number of about 0, about 210, about 220, or about 240.

18. The method of claim 1 , wherein the complex coacervate is a complex coacervate of gelatin and polyphosphate.

19. The method of claim 1 , wherein the loading substance comprises a biologically active substance or a nutritional supplement.

20. The method of claim 1 , wherein the loading substance comprises one or more oils chosen from a microbial oil, algal oil, fungal oil, and plant oil.

21. The method of claim 1 , wherein the loading substance comprises fish oil.

22. The method of claim 21 , wherein the fish oil comprises an Atlantic fish oil, Pacific fish oil, Mediterranean fish oil, light pressed fish oil, alkaline treated fish oil, heat treated fish oil, light and heavy brown fish oil, bonito oil, pilchard oil, tuna oil, sea bass oil, halibut oil, spearfish oil, barracuda oil, cod oil, menhaden oil, sardine oil, anchovy oil, capelin oil, Atlantic cod oil, Atlantic herring oil, Atlantic mackerel oil, Atlantic menhaden oil, salmonid oil, or shark oil.

23. The method of claim 1 , wherein the loading substance comprises an omega-3 fatty acid, and ester of an omega-3 fatty acid, and/or a mixture thereof.

24. The method of claim 23 , wherein the ester of an omega-3 fatty acid comprises an alkyl ester of an omega-3 fatty acid, a monoglyceride of an omega-3 fatty acid, a diglyceride of an omega-3 fatty acid, a triglyceride ester of an omega-3 fatty acid, a phytosterol ester of an omega-3 fatty acid, an ester of an omega-3 fatty acid and an antioxidant, a furanoid ester of an omega-3 fatty acid, and/or a mixture thereof.

25. The method of claim 1 , wherein the loading substance comprises docosahexaenoic acid and/or eicosapentaenoic acid, a C1-C6 alkyl ester thereof, a triglyceride ester thereof, a phytosterol ester thereof, and/or a mixture thereof.

26. The method of claim 1 , wherein the outer shell has an average diameter of from about 1 μm to about 2,000 μm.

27. The method of claim 1 , wherein the primary shell has an average diameter of from about 40 nm to about 10 μm.

28. The method of claim 1 , wherein the loading substance is from about 20% to about 90% by weight of the microcapsule.

29. The method of claim 1 , wherein the encapsulated agglomeration microcapsules are prepared by a process comprising:

(i) providing an emulsion comprising a first polymer component and the loading substance;

(ii) adding a second polymer component to the emulsion;

(iii) adjusting pH, temperature, concentration, mixing speed, or a combination thereof to form an aqueous mixture comprising the primary shell material, wherein the primary shell material comprises the first and second polymer components and surrounds the loading substance;

(iv) cooling the aqueous mixture to a temperature above the gel point of the primary shell material until the primary shell material forms agglomerations; and

(v) further cooling the aqueous mixture to form the outer shell around the agglomeration.

30. The method of claim 29 , comprising adding an antioxidant to the emulsion and/or the aqueous mixture.

31. The method of claim 30 , wherein the antioxidant comprises ascorbic acid, citric acid, or a salt thereof.

32. The method of claim 29 , wherein step (iv) is practiced by cooling the aqueous mixture at a cooling rate of about 1° C. per about 1 to about 100 minutes.

33. The method of claim 32 , wherein the cooling rate is about 1° C. per 5 minutes.

34. The method of claim 29 , wherein step (iv) is practiced by cooling the mixture until the mixture reaches a temperature of from about 5° C. to about 10° C.

35. The method of claim 29 , further comprising step (e) adding a cross-linker to cross-link the shell material.

36. The method of claim 35 , wherein the cross-linker is an enzymatic cross-linker, an aldehyde, tannic acid, alum, or a mixture thereof.

37. The method of claim 35 , wherein the cross-linker is gluteraldehyde.

38. The method of claim 35 , wherein the cross-linker is transglutaminase.