Sequential-Dispersion Particles from Gas Saturated Solutions (SD-PGSS) process was applied to encapsulate lutein with biocompatible polymer excipients to elaborate drug-delivery particles for oral uptake at mild temperatures (38 and 45 °C) under 25 MPa. Polycaprolactone and a polycaprolactone/polyethyleneglycol mixture (1:1 w/w) were selected to modulate in-vitro release. An experimental setup was designed in-house to limit the challenging plugging issues often encountered with the PGSS process. In this study, process yields up to 94% were obtained. The drug precipitation yields varied from 43 to 61% and the homogeneity of lutein dispersion was demonstrated for all conditions. In-vitro release kinetics were performed in phosphate-buffered saline solutions for 8 h. A higher release of lutein was obtained from PCL/PEG blends (∼ 90% in 5 h), whereas only 56% were released from pure PCL formulations. This study highlights the potential of the SD-PGSS process in encapsulating thermosensitive compounds at moderate temperatures. Display omitted •Sequential-dispersion PGSS (SD-PGSS) applied to polymer excipient processing.•Solvent-free SD-PGSS applied to the elaboration of controlled release drug delivery systems.•Lutein encapsulation with biocompatible polymers for oral uptake in AMD mitigation.•Process yields up to 94% under moderate temperatures (38 and 45 °C).•Modulation of lutein release profile from solid formulation.