Continuous Production of Melamine-Formaldehyde Microcapsules Using a Mesostructured Reactor
Ana C. G. Moreira, Yaidelin A. Manrique, Isabel M. Martins, Isabel Fernandes, Alírio E. Rodrigues, José Carlos B. Lopes, Madalena M. Dias
Abstract
A mesostructured NETmix reactor was adapted to develop a continuous process to produce microcapsules, focusing on the steps commonly used in batch formulation: the emulsion and cure. Microcapsules were formed through a polycondensation process by coating Miglyol, a skin-hydrating emollient, with melamine-formaldehyde, which is a resistant shell material with surface smoothness. Different recirculation times were tested for the cure step. Microcapsules show a spherical shape and smooth membrane. Efficiencies of encapsulation of 75%, core contents of 70%, and diameters around 20 μm, ideal range for textile impregnation, were obtained. Scanning electron microscopy shows the integrity of microcapsules on textiles after impregnation and their flexible behavior. The thermogravimetric analysis confirmed the thermal stability of microcapsules up to 210 °C. With the NETmix reactor, it is possible to reduce the cure time of traditional batch formulation in 80%, producing microcapsules with similar characteristics in a continuous process.