Highly Concentrated Nanoemulsions With Sub-100 nm Droplets: Here’s How to Make Them

nanoemulsion samples-1 Producing fast-acting, highly bioavailable, readily water-soluble nanoemulsions of bioactive ingredients—such as cannabis extracts, pharmaceutical and nutraceutical compounds, vitamins, essential oils, and terpenes—has become standard practice for many functional food and beverage manufacturers. Whether crafting beverages, water-based tinctures, gummies, edibles, or other infused products, the ability to reduce the onset time and enhance the bioavailability of incorporated bioactives is critical. The key to achieving these outcomes lies in formulating nanoemulsions with sub-100 nm median droplet sizes [1, 2].

For over a decade, thousands of companies worldwide have relied on NanoStabilizer®-LT—a groundbreaking all-in-one blend of tasteless, food-grade nano-emulsification ingredients developed by Industrial Sonomechanics (ISM). When used with ISM’s ultrasonic processors or third-party high-pressure homogenizers, NanoStabilizer®-LT can produce permanently stable nanoemulsions with extremely small median droplet sizes at various bioactive concentrations. At concentrations up to 50 mg/ml, these formulations typically achieve median droplet sizes of 25–30 nm, far exceeding the sub-100 nm requirement and delivering exceptionally favorable pharmacokinetic parameters, as demonstrated in a recent pre-clinical study [3].

What about much higher concentrations?

As the industry continues to evolve, the demand for nanoemulsions with significantly higher bioactive concentrations has grown. Many companies now require formulations that retain short onset times and high bioavailability even at elevated concentrations. Recently, we have received numerous inquiries about producing nanoemulsions with CBD, Δ8 and Δ9 THC, terpenes, and other ingredients at concentrations as high as 200 mg/ml (20%) while achieving sub-100 nm median droplet sizes. We are thrilled to confirm that this is not only achievable but also delivers exceptional results.

Formulating High-Concentration Nanoemulsions

As explained in this article, when creating highly translucent nanoemulsions with bioactive extract concentrations up to 50 mg/ml (5%), we recommend using a 5:1 mass ratio of NanoStabilizer®-LT to the extract. This approach typically yields median droplet sizes of 25–30 nm.

For significantly more concentrated nanoemulsions, this ratio must be reduced to maintain at least 50% water content in the formulation, ensuring stability and acceptable viscosity. For example, a 200 mg/ml (20%) bioactive extract concentration requires a NanoStabilizer®-LT to extract ratio of 1.5:1, resulting in the following formulation:

20% bioactive extract
30% NanoStabilizer®-LT
50% water

To achieve optimal results, we recommend the following:

Use the Right Equipment: ISM’s lab-, bench-, and industrial-scale ultrasonic processors deliver the high amplitudes and cavitation intensities necessary for efficient nano-emulsification.
Follow the Recommended Protocols: ISM provides detailed guides and training to help you achieve consistent success.
Leverage Expert Support: Our team is ready to assist with troubleshooting and fine-tuning your formulations to meet your specific goals.

What Results to Expect

For most oil-soluble bioactive extracts, the correctly processed formulation outlined above typically yields a median droplet size (d50 value) slightly below 100 nm. While higher concentrations are achievable, it is expected that both the d50 value and product viscosity will increase proportionally.

By using the same or a slightly lower NanoStabilizer®-LT to extract ratio, it is possible to produce high-performance nanoemulsions with bioactive concentrations exceeding 200 mg/ml (20%), while maintaining excellent stability and bioavailability.

Ready to Raise the Bar?

Discover the full potential of NanoStabilizer®-LT and create water-soluble bioactive products that truly stand out in the market. Contact us today to get started!

References

Sonomechanics Blog