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Aim of this work is to apply protective and homogeneous shellac coating layers on the surface of hydrophilic open-pore cellulose aerogel particles with low densities ≤ 0.1 g/cm3 and high specific surface areas in the range of ~ 400–450 m2/g while keeping the aerogels’ microstructure intact during processing. For this purpose, an innovative miniaturized spouted bed setup was used. Successful process settings for application of enclosed films on aerogel surfaces without intrusion of coating material into the pores were determined. Precise control of coating layer thickness in the range of 10–50 µm was achieved due to variation of coating solution amount without agglomeration and clogging events occurring during processing. Comparison of bulk densities and specific surface areas before and after coating proved the intactness of the porous structure. Coating of particles loaded with vanillin led to controlled release, enhancing release half-life times from 20 to 1600 min. Overall, a successful strategy for coating of organic low-density aerogels was developed.

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