9 Surprising Ways Industries Rely on Electrospraying for Manufacturing

In manufacturing, every second counts. And as companies strive to keep up with demand, finding faster and more efficient production methods is crucial. One such method is electrospraying – a technology that has quietly been revolutionizing various industries. But what is electrospraying, and how does it work? This article will explore the concept of electrospraying and take a closer look at industries that rely on this innovative technology to meet their production needs.

Photographer: Lalit Kumar

What is Electrospraying?

Electrospraying is a process that uses electrically charged particles to produce a fine spray of liquid droplets or solid particles. Using specialized electrospraying equipment, a high voltage is applied to a liquid or solid material, creating an electric field that causes the material to form into droplets or particles. These droplets or particles can then be directed onto a substrate, such as a surface or object, where they can form a thin film, coating, or other type of layer.

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Electrospraying is a highly precise and efficient process that can produce materials with a wide range of sizes, shapes, and properties. Materials commonly used in electrospraying include:

  • metals
  • polymers
  • ceramics, and
  • biological materials,

among others.

Compared to other manufacturing methods, electrospraying can produce materials with superior properties, such as improved strength, durability, and functionality.

Electrospraying in the Pharmaceutical Industry

Electrospraying has become an important tool in the pharmaceutical industry for producing drug particles with improved bioavailability and efficacy. Here are some of the ways that electrospraying is being used in pharmaceutical manufacturing:

1. Micro- and Nano-Particle Production

Using electrospraying equipment, drugs can be transformed into micro- or nano-sized particles, which can then be easily absorbed by the body. This can lead to faster drug delivery, improved therapeutic effects, and reduced side effects.

2. Inhalable Drug Formulations

Electrospraying is also used in the production of inhalable drug formulations, such as asthma medications and vaccines. By creating particles of specific sizes and shapes, electrospraying can help optimize the delivery of drugs to targeted areas of the body, such as the lungs or digestive system.

3. Controlled Release Formulations

Electrospraying can also be used to create controlled release formulations, in which drugs are released slowly over time. This can be especially useful for drugs that require long-term treatment or for delivering drugs to specific parts of the body.

Electrospraying in the Food Industry

Electrospraying is also being used in the food industry to create functional food ingredients with enhanced properties. Here are some ways that electrospraying is being used in food manufacturing:

4. Encapsulation of Bioactive Compounds

Electrospraying can be used to encapsulate bioactive compounds, such as vitamins and antioxidants, in food matrices. This can help protect these compounds from degradation and improve their stability during storage.

5. Flavor and Texture Enhancement

Electrospraying can also be used to enhance the flavor and texture of food products. For example, it can be used to create coatings for snacks that provide a crunchy texture or to add flavorings to beverages.

6. Food Safety

Electrospraying can also be used for food safety applications, such as the creation of antimicrobial coatings for food packaging materials. These coatings can help prevent the growth of harmful bacteria and increase the shelf life of food products.


Electrospraying in the Textile Industry

Electrospraying is also being used in the textile industry to create advanced materials with unique properties. Here are some ways that electrospraying is being used in textile manufacturing:

7. Fabric Coatings

Electrospraying can be used to create thin, uniform coatings on fabrics. These coatings can enhance the fabric’s properties, such as its water repellency or durability.

8. Smart Textiles

Electrospraying can also be used to create smart textiles with sensing or energy-harvesting capabilities. For example, electrospraying can be used to create conductive coatings on textiles that can be used for wearable sensors or energy-harvesting devices.

9. Nanofiber Production

Electrospraying can also be used to produce nanofibers for use in textiles. These nanofibers can be used to create high-performance textiles with improved properties, such as increased strength and flexibility.


Electrospraying is a versatile manufacturing technique that has found its way into unexpected industries, such as food, pharmaceuticals, and textiles. With its ability to create unique and functional materials, electrospraying is revolutionizing the way we produce goods. As technology continues to advance, it will be exciting to see how electrospraying evolves and impacts even more industries in the future. The possibilities are endless, and the potential for innovation is immense.

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