The present work focuses on the production of topical anti-cellulite devices through a supercritical one-step process consisting of the polymer foaming and impregnation of caffeine into PLA/PBAT/CaCO3 films to obtain a biocompatible and biodegradable patch. Field Emission Scanning Electron Microscopy analysis revealed that porosities were formed in the polymeric support when in contact with the supercritical CO2. Atomic force microscopy revealed the presence of caffeine on the polymer surface in the form of needles. The impregnation kinetics determined at 17.0 MPa showed an increase in caffeine loadings with the contact time (up to 16.5% and 23.0% wcaffeine/wfilm at 40 °C and 35 °C, respectively), corresponding to higher caffeine loadings than the ones contained in commercial products (about 3%). The release of caffeine was simulated by UV–vis spectrophotometry: pure caffeine dissolved instantly in the dissolution medium, whereas its release was prolonged up to 2 days when it was impregnated within the PLA/PBAT/CaCO3 film.
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