Optimized Thyme Oil Single and Double Emulsion for Sustainable Animal Health Applications

Thyme oil (TO) is emerging as a promising candidate to counteract antimicrobial resistance due to its renowned antimicrobial and anti-inflammatory properties. However, rapid gastric absorption of its bioactive compounds limits its intestinal delivery, where its action is required, so the protection of these components is necessary. This pilot study optimized TO-loaded emulsions for targeted intestinal release. High-shear homogenization and membrane emulsification were compared to formulate single oil in water (O/W) and double water in oil in water (W/O/W) emulsions, screening emulsifiers (lecithin, Tween 20, Tween 80) and functional biopolymers (pectin, sodium alginate). High-shear homogenization with lecithin (0.5%), pectin (1.80%), and sodium alginate (0.2%) yielded stable submicron O/W emulsion (Span = 0.5; d(v,0.5) = 0.21 µm), achieving electrostatic stabilization (ζ-potential = −51.5 ± 1.5 mV) at a target poultry dosage. A pH-responsive behavior was observed: protective hydrogel formed in gastric conditions (d(v,0.5) = 2.64 µm) and maintained stability at intestinal pH (d(v,0.5) = 3.03 µm). Membrane emulsification enabled precise droplet control under mild conditions, producing monodisperse O/W emulsions (d(v,0.5) = 38–59 µm; Span ≤ 1.0) and W/O/W double emulsions (d(v,0.5) = 26.5 µm; Span = 0.6) with ultra-low interfacial tension (0.52 mN·m−1). Repeated membrane passes reduced droplet size to ~6.6 µm. These systems represent a foundational step toward bioactive intestinal delivery, providing a viable antibiotic-free strategy for sustainable livestock production.