Novel methods for liposome production have been developed and improved over the years, with the aim of overcoming the drawbacks related to the traditional methods. Differently from the liposomes produced using the conventional methods, vesicles produced by these new methods are mainly unilamellar and show a more homogeneous size distribution (lower values of PDI). Therefore, post-processing techniques such as sonication or extrusion are rarely required. Moreover, conventional methods are based on the use of organic solvents and detergents, which can limit their use in food and cosmetics, and are often not environmentally friendly. Currently, research efforts around liposomes focused on the optimization of green technologies that can be scaled-up to industrial levels.
3.2.9. Supercritical Technologies
Supercritical fluid technologies have emerged as attractive methods for producing liposomes [
56]. CO
2 is the most commonly used gas in supercritical fluid technology for several reasons, including low cost, non-toxicity, safety, and large availability. It is therefore considered a safe gas for use in food, pharmaceutical, and cosmetic applications [
56]. Most processes of liposome production that uses supercritical CO
2 (sc-CO
2) involves dissolving a lipid mixture in a solution of CO
2 at high pressure and temperature. The CO
2 solution then acts as a solvent for the lipids, leading them to self-assemble and to form vesicles. The pressure and temperature of the CO
2 solution can be easily controlled to modify the size and shape of the samples. One of the key advantages of sc-CO
2-based processes is the absence of organic solvents, which can be toxic and difficult to remove from the final product. Besides being non-toxic, CO
2 readily evaporates, leaving no residue in the final product. Over the years, many supercritical technologies for liposomes production have been explored, and some of them are discussed below.
- Depressurization of expanded liquid organic solution into aqueous solution (DELOS-susp): this is a compressed fluid-based method that enables the reproducible and scalable production of nanovesicular systems with exceptional physicochemical properties, including uniformity, morphology, and particle size [
95]. To prepare the samples, the reagents are initially dissolved in an organic solvent and subsequently treated using pressurized CO
2 until saturation. Then, the sample is rapidly depressurized from the bottom, experiencing a significant pressure drop from 10 MPa to ambient pressure. CO
2 molecules are released from phospholipid bilayers to temporarily disrupt them into highly dispersed phospholipids that undergo a rapid reorganization due to hydrophobic and van der Waals interactions, then packing themselves into liposomes [
96,
97]. This process produces small and uniform liposomes due to the high rate of depressurization and can be used to encapsulate thermo-sensitive materials since works under slight conditions [
98]. Adaptations of this method have been proposed to remove the need for organic solvents or surfactants during production, some of them still resulting in SUVs at high storage stability [
99].
- Depressurization of expanded solution into aqueous media (DESAM): this is an alternative dense gas technology, in which pressure requirements for liposome production are reduced to 4 - 5.5 MPa [
100]. This method involves dissolving lipids in a solvent and pressurizing the solution with a dense gas to create an expanded lipid solution. The expanded solution is, then, released in a controlled manner into heated aqueous media, with pressure maintained through the addition of more dense gas. Care is taken to keep the pressurization and expansion below a certain threshold to avoid solute precipitation. The dense gas and solvent can be separated and reused. The resulting fine droplets disperse the lipid in the aqueous phase and improve component interaction, resulting in uniform liposome formation. The high temperature in the vesicle formation chamber can also aid in removing organic solvent from the product [
100]. Liposomes produced by this method are mainly unilamellar, with sizes ranging from 50 to 200 nm, PDI not exceeding 0.29, and highly stable for periods of 8 months [
142]. Recently, a continuous process named nano-carrier by a continuous dense gas (NADEG) technique appeared as an evolution of the DESAM method [
101,
102].
- Rapid expansion of supercritical solution (RESS): this is a technology currently used for micronization, co-precipitation and encapsulation. Lipids are dissolved in a mixture of sc-CO
2 plus 5 - 10% v/v of ethanol within an extractor. This primary dissolution in a co-solvent (ethanol) is strictly necessary because the natural phospholipids are poorly soluble in sc-CO
2 [
103]. This solution is then released through a heated small nozzle in a low-pressure chamber and mixed with an aqueous solution. A rapid depressurization follows, and the pressure drop results in the lipids desolvation, which favors the formation of layers around the droplets due to solute supersaturation. Small particles are obtained from the gas stream [
104,
105]. This process produces small particles, with a uniform size. However, this method shows problems such as the difficult separation between vesicles and co-solvents during depressurization, which increases production costs [
106]. Nevertheless, the RESS method is one of the most studied supercritical technologies for vitamin-loaded liposome production [107-112]. Han et al. [
154] produced vitamin E acetate-loaded liposomes using an optimized RESS process without any organic solvent. Operating conditions were controlled using the single-factor analysis and the response surface methodology combined with Box-Behnken design. Samples were produced using polyvinyl acetate grafted phospholipids and vitamin E acetate in a 6.35:1 mass ratio and resulted in vesicles characterized by EE% = 93%, size of 247 nm, PDI of 0.295, and zeta potential of -42.55 mV. Jiao et al. [
108] also used the Box-Behnken design to optimize the process parameters for the production of vitamin C-loaded liposomes using PC as wall material. Vesicles presented size of 270 nm, PDI of 0.254, zeta potential of -41.7 mV, and EE% of 75%. Sharifi et al. [
111] produced ironized multivitamin-loaded liposomes containing lecithin, Chol, iron sulfate, and hydrophilic and hydrophobic vitamins (C and E, respectively) by a new venturi-based method called Vent-RESS, in which RESS was combined with Bernoulli principles. Liposomes with unimodal size distribution were obtained and EE% of bioactive molecules were improved when operating pressure increased from 12 to 18 MPa. The Vent-RESS process was also used in Jash, Ubeyitogullari, & Rizvi [
110] to produce vitamin C-vitamin E-co-loaded liposomes in milk fat globule membrane phospholipids (MFGM) or sunflower phosphatidylcholine (SFPC). These authors verified that MFGM-based ULVs were smaller in size than SFPC-based ones (533 nm vs. 761 nm, respectively), with higher zeta potential (-57 mV vs. -37 mV, respectively).
- Supercritical reverse phase evaporation process (scRPE): this is a batch method developed by Otake et al. [
113] that enables the efficient formation of liposomes using a one-step process. It acts similarly to the RPE method; but, in this case, sc-CO
2 substitutes the organic solvent. It involves the mixing of sc-CO
2, lipids, and ethanol and, then, the introduction of small amounts of water to generate a liposome dispersion through an emulsion formation. The procedure is carried out in a stirred volume cell at a temperature above the lipid phase transition temperature. As the aqueous solution is gradually added to the reactor, sc-CO
2 is released, resulting in the formation of liposomes upon depressurization [
97,
114]. Some years later, Otake et al. [
115] optimized the scRPE method in a way that organic solvents were no longer needed. Zhao & Temelli [
116] developed a similar process in which liposomes are formed by simple pressurization and depressurization of a sc-CO
2-lipid-based aqueous solution. Liposomes size can vary from 100 nm to 1.2 µm by using this method, being SUVs or MLVs [
117].
- Supercritical antisolvent (SAS): it involves a continuous spraying of an organic solution of phospholipids into sc-CO
2, which serves as an antisolvent for phospholipid precipitation. As soon as sc-CO
2 contacts the liquid phospholipid phase, it quickly diffuses and divides the liquid phase in tiny droplets. At the same time, the organic solvent evaporates from the droplets as a consequence of the dissolution in sc-CO
2. This mass transfer creates a supersaturation of phospholipids within the droplets, leading to the formation of small phospholipid particles through nucleation and aggregation. A pure CO
2 washing step can be performed to remove any trace of the organic solvent. Finally, spherical micro- or nano-liposomes are formed upon hydration with an aqueous buffer. Xia et al. [
118] produced vitamin D
3-loaded proliposomes using a SAS based technology. Hydrogenated PC was used as a lipid source. Conditions as T = 45 °C, P = 8 MPa and 15% w/w lipid to vitamin D
3 ratio resulted in hydrated liposomes with an EE% = 100% and an effective loading of 12.9%.
- Supercritical assisted liposome formation (SuperSomes): this is a continuous sc-CO
2 based process proposed by Reverchon and co-workers [
119] in which, differently from the other methods, water particles are first formed by atomization and, then, covered by lipids dissolved in an expanded liquid mixture. The expanded liquid mixture is composed of phospholipids, ethanol and sc-CO
2. The main idea is that lipids reorganize themselves around the water droplets forming inverted micelles, which tend to form liposomes as soon as they come in contact with a water pool located at the bottom of the vessel [
120,
121]. Process parameters, as water flow rate, injector diameter, phospholipid concentration, pressure, and gas to liquid ratio, have been constantly optimized during SuperSomes studies [
122]. This apparatus has been efficiently used to encapsulate both hydrophobic and hydrophilic bioactive molecules [123-126]. The process is reproducible, therefore, allowing a good control of vesicle size distribution, and nanometric vesicles at high EE%. Recent studies showed the feasibility of using SuperSomes apparatus to encapsulate vitamin D
3 into nanoliposomes [
127,
128]. In both studies, liposomes were produced using different ratios of soy hydrogenated and egg-yolk nonhydrogenated phospholipids. In Chaves et al. [
127], samples produced using only egg-yolk phosphatidylcholine presented sizes of 132 nm. Also, a 10 mL/min water flow rate also led to highly homogeneous vesicles produced using a maximum of 20% of soy hydrogenated phospholipids with size of 218 nm, PDI of 0.253, and an EE% of 89%. In Chaves et al. [
128], the effect of the incorporation of vitamin D
3 in curcumin-loaded liposomes was investigated. The addition of vitamin D
3 reduced the overall size of liposomes from approximately 220 nm to 130 nm; but also promoted a decrease in EE% of curcumin. The authors stated that this behavior was probably due to the competition between the two hydrophobic bioactives for the inner region of lipid bilayers.
- Aerosol solvent extraction system (ASES): this method was originally developed to produce a sterile product containing a biologically degradable carrier and a molecule embedded within it [
129]. Using this technique, organic liquids are sprayed through a nozzle into a bulk of sc-CO
2, which quickly extracts them and facilitates the rapid precipitation of solutes from the solution. After a short period of drying with circulating sc-CO
2, the residual solvent can be easily removed from the precipitates. This is because the pressure reduction during particle formation and drying only affects the circulating supercritical gas phase containing the organic liquids. The ASES process has been successfully applied to liposome preparation, enabling the production of dry and reconstitutable pharmaceutical liposomes suitable for large-scale manufacturing [
130,
131].
- Particles from gas saturated solution (PGSS): this is a cutting-edge method that uses supercritical fluids to produce particles of a precise size. This process operates at mild temperatures, generally between 40 - 60 °C, in an inert environment, and uses CO
2 and water as solvents [
132]. It offers an alternative to conventional techniques such as spray drying and freeze drying. One of the main advantages of the PGSS-drying method is its efficient atomization, due to the rapid release and expansion of gas from the solution during depressurization from supercritical to ambient conditions. This technique also allows a drying at lower temperatures in the spray tower, reducing the exposure of the bioactive material to harmful high temperatures [
133]. Moreover, it enables the use of carrier materials that cannot be processed by conventional spray drying due to their low melting temperature.