Caffeine encapsulation using zein nanoparticles for bitterness masking and sustained release

Overview

Caffeine is one of the most widely consumed bioactive compounds, valued for its ability to stimulate the central nervous system, increase alertness, and relieve fatigue. However, its strong bitter taste and rapid absorption limit its use in food and beverage applications, producing unpleasant aftertaste and a short effect window of only 2–3 hours per dose. NUCAPS Nanotechnology proposes encapsulating caffeine within zein protein nanoparticles to mask bitterness and achieve a controlled, slow-release profile. The formulation uses GRAS (Generally Recognized As Safe) materials, making it suitable for food and nutraceutical applications while targeting a Technology Readiness Level of 6–8.

Technical specifications

• Encapsulation matrix: Zein, a natural plant-derived protein, used as the encapsulating material for caffeine.
• Particle characteristics: Particles above 250 nm in size, meaning they are not classified as nanomaterials under current regulatory definitions.
• Key parameters studied: Particle size, polydispersity index (PDI), zeta potential, process yield, theoretical payload, and production cost.
• Functional benefits: Bitterness masking of caffeine and sustained release in simulated gastrointestinal conditions.
• Analytical methods: HPLC-based quantification of caffeine content and in vitro release assays to characterize the release pattern.
• Scalability: Formulation designed for pilot-plant scale-up, with at least three independent batches prepared on different days to validate robustness, yielding approximately 1 kg samples.
• Technology transfer: Includes development of a preparative process protocol to support industrial adoption.

Technology readiness level

The underlying zein encapsulation platform has been validated by NUCAPS across multiple bioactive substances, including antioxidants, natural extracts, and probiotics, with established protocols for particle characterization and in vitro release testing. The caffeine-specific project follows a phased development plan: a proof-of-concept at laboratory scale (approximately 2 weeks), formulation optimization with HPLC method validation (approximately 1 month), in vitro gastrointestinal release studies (approximately 2 weeks), pilot scale-up (approximately 1 month), and a final technology transfer phase. The target Technology Readiness Level is 6–8, reflecting progression from demonstrated prototype to pilot-scale production ready for industrial transfer.