Vitamin E Microencapsulation via Electrohydrodynamic Techniques for Potential Use in Skin Care and Dermatological Applications

Vitamin E is widely used in cosmetics and dermatological applications for its antioxidant, anti-inflammatory, and healing properties, yet its industrial use is limited by poor stability and bioavailability. To address these challenges, this study developed zein-based microstructures encapsulating vitamin E using electrohydrodynamic (EHD) techniques and evaluated how zein concentration affects morphology and release behavior. The SEM analysis showed that biopolymer (zein) concentration significantly affects microstructure morphology. At low concentrations (1%, 5%, and 15% (<i>w</i>/<i>v</i>)), micro/nanoparticles are formed, and high concentrations (30% (<i>w</i>/<i>v</i>)) yielded only fibers. The average size of the structures produced with zein (1-15% <i>w</i>/<i>v</i>) ranged from 0.38 to 0.90 µm, as measured using the program ImageJ (v1.54d). Structures containing vitamin E were generally smaller than those without. For electrospun fibers made with 30% zein, diameters ranged from 0.49 to 0.74 µm, with vitamin E-containing fibers also being thinner. Conductivity also influenced morphology; higher conductivity developed fibers, while lower conductivity formed particles. The solution with 15% (<i>w</i>/<i>v</i>) zein + 1% (<i>w</i>/<i>w</i>) vitamin E showed a conductivity of 1276 μS, similar to the 15% zein solution (1280 μS), indicating that vitamin E addition had no significant effect on conductivity. Release assays revealed that structures produced with low zein concentrations led to immediate release, while structured made with higher concentrations, prolonged release. A preliminary cosmetic formulation test has been conducted. The vitamin E microstructures were successfully incorporated into aloe vera hydrogel and coconut oil to show their potential for cosmetic applications.