Cao, X.Luo, X.Heydari, A.Barros, S.M.Kirk, B.P.Tang, Y.Raston, C.L.2025-07-082025-07-082025Journal of Cleaner Production, 2025; 494:145006-1-145006-140959-65261879-1786https://hdl.handle.net/2440/145766This study investigates the production of fatty acid ethyl esters (FAEE) for organic cosmetic applications, focusing on adhering to green chemistry principles and organic cosmetic standards. To achieve this, the vortex fluidic device (VFD), a high-efficiency thin-film processing platform, was explored to enhance FAEE production from Canola and Tung oil at room temperature. By utilising the central composite design technique, this study systematically varied the rotational speed of the standard VFD, the catalyst concentration, and the ethanol-to-oil ratio, aiming for the highest product yield in 20 min. Scale-up production of Canola-FAEE and Tung-FAEE was further achieved with an upsized VFD, using a benchtop method as the control. The yield of Canola FAEE reached 96% using the upsized VFD processing, demonstrating a 10% improvement over the bench-top method. Additionally, the FAEE transesterified from Tung oil with a relatively high acid value of 3.7 mg/g exhibited an increased yield from 53.2% to 90.5% while preserving the triple conjugated C=C of α-eleostearic acid. In the formulation of skincare emulsions, the FAEE-based emulsion showed smaller particle sizes (350–370 nm) and superior stability compared to oil-based counterparts after 5 days of storage at 50⁰C. This research establishes an efficient protocol for producing cosmetic-grade FAEE using VFD technology, highlighting its potential for skincare formulations.en© 2025 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license ( http://creativecommons.org/licenses/by/4.0/ ).FAEE; canola oil; tung oil; vortex fluidic device; organic cosmetic; CCDJournal article10.1016/j.jclepro.2025.145006729856Kirk, B.P. [0000-0001-9347-7518]