Heat stable vitamin D3 loaded nanostructured lipid carriers (NLCs) were developed by edible solid lipids with high melting points (beeswax and margarine) and alpha-tocopherol as liquid oil. These NLCs were coated by gelatin to be spray dried and easily portable. The effect of solid lipid type (beeswax or margarine), solid-to-liquid lipid ratio, and surfactant composition (Tween-80/polyglycerol ester) on mean particle size, polydispersity index (PDI), and encapsulation efficiency (EE) of NLCs were studied. Results showed that the beeswax-based NLC had higher mean size and EE (%) than the margarine-based ones. The morphology and polymorphic structures of selected formulations of NLCs were studied and compared with their solid lipid nanoparticles (SLNs). Gelatin was used for coating NLC particles during spray drying of NLC suspensions. Vitamin D3 was stable in both beeswax and margarine-based NLCs during two months’ storage at ambient temperature. However, the stability of vitamin D3 in the beeswax-based NLCs was higher than in margarine-based ones during cooking and frying of oil.
