Black seed oil (BSO) has various therapeutics effects; however, its unpleasant taste and restricted availability in the market in the form of raw oil or soft/hard gelatine capsules necessitates the need for a new formulation that is more suitable for children and elderlies. This study aimed to optimize the ionic gelation parameters for the large-scale production of BSO-loaded alginate beads. Firstly, alginate concentration, dripping distance, dripping flow rate, and high voltage application were optimized by using the design of experiments. The dripping flow rate was scaled-up using a multi-nozzle from 2 to 24mL/min. The beads were fabricated spherically with an acceptable uniform size of 1.99 ± 0.06mm when no voltage was applied. The application of 6 kV on the multi-nozzle resulted in non-uniform bead sizes with a higher standard deviation. The calcium chloride/gelation bath concentration was optimized at 2% w/v to cure the beads for 25-60min with no significant differences...

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