Microplastic-free microcapsules for environmentally conscious formulated products: materials, performance and industrial perspectives

Abstract

Microplastic pollution poses an environmental and public health concern because persistent particles can disperse through air,water, soil, and biological systems, making recovery and long-term risk management extremely difficult. In addition to fragmented plastic waste, synthetic polymer microparticles are intentionally added to formulated products for functional benefits. Regulations such as the European Union Registration, Evaluation, Authorisation and Restriction of Chemicals restriction on intentionally added synthetic polymer microparticles, are driving their removal or replacement. Microcapsule-based delivery systems form an important subset of this challenge in agrochemicals, detergents, personal care products, coatings, and household formulations, where polymeric shells protect active ingredients and control their release. Replacing these non-biodegradable shells is challenging because they provide desirable mechanical strength, barrier properties, high payload, and controlled release in demanding formulations. This mini-review critically examines emerging microplastic-free encapsulation strategies, including inorganic shells, biobased polymers, organic–inorganic hybrids, biodegradable aliphatic polyesters, and supramolecular assemblies formed at emulsion interfaces. These approaches show that 1 microplastic-free encapsulation is feasible and can sometimes match conventional microcapsules, but scalability, manufacturing simplicity, and validated environmental fate remain major barriers. Future progress requires integrated design strategies that combine performance, scalable processing, environmental validation, and regulatory compliance. Direct benchmarking against conventional microcapsules and lower-energy manufacturing routes will be essential for next-generation delivery systems aligned with circular economy and net zero goals.

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Higher Education Press 2027

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