Application of Hot-Melt Extrusion in Modifying the Solubility of Lycopene

Lycopene is a potent antioxidant carotenoid with significant health-promoting properties. However, its practical application is limited by poor water solubility. This study aimed to enhance lycopene dispersibility through the development of solid dispersions obtained by hot-melt extrusion (HME). Polymeric carriers composed of polyvinylpyrrolidone K30 (PVP K30), phosphatidylcholine, and xylitol were designed to achieve optimal processing conditions and thermal stability. Nine formulations containing 10–30% lycopene were prepared and characterized using thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), X-ray powder diffraction (XRPD), Fourier transform infrared spectroscopy (FT-IR), and dispersibility testing. TGA confirmed the thermal stability of lycopene at the extrusion temperature (150 °C). DSC and XRPD analyses indicated partial amorphization of lycopene in the extrudates, while FT-IR spectra revealed molecular interactions between lycopene and carrier components, particularly hydroxyl and carbonyl groups. Among the tested systems, the formulation containing PVP K30 and xylitol without phosphatidylcholine exhibited the highest dispersibility (1.0484 mg/mL after 3 h). Dispersibility decreased with increasing lycopene content. These findings demonstrate that HME is an effective technique for producing partially amorphous lycopene dispersions with improved dispersibility, and that polymer–polyol systems are particularly promising carriers for enhancing lycopene bioavailability.