Melatonin presents a dual manufacturing challenge: it is poorly water-soluble in its crystalline form and highly sensitive to light and oxidative conditions, which can compromise active content during bulk powder handling, blending, and long-term storage. Our liposomal encapsulation process addresses both issues at the production level.

Through controlled high-shear emulsification, melatonin is embedded within the phospholipid bilayer of nano-scale vesicles. The resulting liquid liposomal dispersion is converted into a dry, free-flowing powder via spray-drying under precisely monitored inlet/outlet temperature parameters. This dry powder format eliminates cold-chain logistics, enables standard powder-handling equipment integration (V-blenders, ribbon blenders, capsule fillers), and maintains consistent melatonin content across every production batch — a critical parameter for manufacturers running high-throughput, automated filling lines.