Optimization of a spray-drying process for the production of maximally viable microencapsulated Lactobacillus pentosus using a mixture of starch-pulque as wall material

Preparation of microcapsules and evaluation of their biocontrol efficacy

In this study, a combination of Serratia nematophila L2 and Bacillus velezensis W24 was used to biocontrol Sclerotinia sclerotiorum. When the mixed ratio of L2 to W24 was 1:1, the inhibition rate on the growth of S. sclerotiorum was 88.1 %. To gain a large number of bacteria, the culture medium and conditions were optimized. When the medium formula involved molasses (8.890 g/L), soy peptone (6.826 g/L), and NaCl (6.865 g/L), and the culture conditions were 32 °C, inoculum 4%, rotation speed 200 rpm, and pH 7, the maximum amounts of bacterial cells obtained. In order to prepare microcapsules, spray drying conditions were optimized. These conditions included the soluble starch concentration of 30 g/100 mL, the inlet air temperature of 160 °C, and the feed flow rate of 450 mL/h. Under these optimized conditions to prepare microcapsules, the mixed strain (L2 and W24) exhibited a survival rate of 93.9 ± 0.9% and a viable bacterial count of 6.4 × 1012 cfu/g. In addition, microcapsules (GW24Ms) which contained strains L2 and W24 had good storage stability. In the pot experiment, GW24Ms could effectively reduce the disease of soybean plants and the control effect was 88.4%. Thus, the microbial agent represents a promising biocontrol solution for managing Sclerotinia in soybean.

Membrane Emulsification as an Emerging Method for Lacticaseibacillus rhamnosus GG® Encapsulation

Techniques capable of producing small-sized probiotic microcapsules with high encapsulation yields are of industrial and scientific interest. In this study, an innovative membrane emulsification system was investigated in the production of microcapsules containing Lacticaseibacillus rhamnosus GG® (Lr), sodium alginate (ALG), and whey protein (WPI), rice protein (RPC), or pea protein (PPC) as encapsulating agents. The microcapsules were characterized by particle size distribution, optical microscopy, encapsulation yield, morphology, water activity, hygroscopicity, thermal properties, Fourier-transform infrared spectroscopy (FTIR), and probiotic survival during in vitro simulation of gastrointestinal conditions. The innovative encapsulation technique resulted in microcapsules with diameters varying between 18 and 29 μm, and encapsulation yields > 93%. Combining alginate and whey, rice, or pea protein improved encapsulation efficiency and thermal properties. The encapsulation provided resistance to gastrointestinal fluids, resulting in high probiotic viability at the end of the intestinal phase (> 7.18 log CFU g-1). The proposed encapsulation technology represents an attractive alternative to developing probiotic microcapsules for future food applications.

Graphical Abstract

Supplementary Information

The online version contains supplementary material available at 10.1007/s11947-023-03099-w.

Optimization of spray drying process parameters for the food bioactive ingredients

Spray drying (SD) is one of the most important thermal processes used to produce different powders and encapsulated materials. During this process, quality degradation might happen. The main objective of applying optimization methods in SD processes is maximizing the final nutritional quality of the product besides sensory attributes. Optimization regarding economic issues might be also performed. Applying optimization approaches in line with mathematical models to predict product changes during thermal processes such as SD can be a promising method to enhance the quality of final products. In this review, the application of the response surface methodology (RSM), as the most widely used approach, is introduced along with other optimization techniques such as factorial, Taguchi, and some artificial intelligence-based methods like artificial neural networks (ANN), genetic algorithms (GA), Fuzzy logic, and adaptive neuro-fuzzy inference system (ANFIS). Also, probabilistic methods such as Monte Carlo are briefly introduced. Some recent case studies regarding the implementation of these methods in SD processes are also exemplified and discussed.

Research opportunities: Traditional fermented beverages in Mexico. Cultural, microbiological, chemical, and functional aspects

In Mexico, close to 200 fermented products have been described, of which, approximately 20 are beverages. They were obtained through rustic and ancestral fermentation methods by different indigenous Mexican communities; most of them were used in ceremonies, agricultural work, and other occasions. For their elaboration, different substrates obtained from plants are used, where uncontrolled and low-scale spontaneous anaerobic fermentation occurs. In Mexico, some of these products are considered as nutritional sources and functional beverages; the study of those products has revealed the presence of multiple compounds of biological importance. Additionally, elder generations attribute healing properties against diverse illnesses to these beverages. The aim of this review is to highlight the available information on twelve traditional Mexican fermented beverages, their traditional uses, and their fermentation processes along with toxicological, chemical, nutritional, and functional studies as seen from different areas of investigation. In the literature, pulque, cocoa, and pozol were the beverages with the greatest amount of described health properties; sendechó and guarapo were less characterized. Polyphenols, gallic and ferulic acid, anthocyanins and saponins were the most abundant molecules in all beverages. Finally, it is important to continue this research in order to determine the microorganisms that are involved in the fermentation process, as well as the organoleptic and beneficial properties they lend to the traditional Mexican fermented beverages.

Optimizing viability and yield and improving stability of Gram-negative, non-spore forming plant-beneficial bacteria encapsulated by spray-drying

This study investigates methods to commercialize safer alternatives to chemical pesticides that pose risks to human safety and the environment. Spray-drying encapsulation of the plant-protective, antifungal bacterium Collimonas arenae Cal35 in in situ cross-linked alginate microcapsules (CLAMs) was optimized to minimize losses during spray-drying and maximize yield of spray-dried powder. Only inlet temperature significantly affected survival during spray-drying, while inlet temperature, spray rate, and alginate concentration significantly affected yield of spray-dried powder. Lowering inlet temperature to 95 °C provided the greatest survival during spray-drying, while increasing inlet temperature and lowering spray rate and alginate concentration produced the highest yield. Without the CLAMs formulation, Cal35 did not survive spray-drying. When Cal35 was encapsulated in CLAMs in the presence of modified starch, shelf survival was extended to 3 weeks in a low oxygen, low humidity storage environment. Cal35 retained its antifungal activity throughout spray-drying and shelf storage, supporting its potential use as a formulated biofungicide product.

Challenges associated with spray drying of lactic acid bacteria: Understanding cell viability loss

Lactic acid bacteria (LAB) cultures used in food fermentation are often dried to reduce transportation costs and facilitate handling during use. Dried LAB ferments are generally lyophilized to ensure high cell viability. Spray drying has come to the forefront as a promising technique due to its versatility and lower associated energy costs. Adverse conditions during spray drying, such as mechanical stress, dehydration, heating, and oxygen exposure, can lead to low LAB cell viability. This reduced viability has limited spray drying's industrial applications thus far. This review aims to demonstrate the operations and thermodynamic principles that govern spray drying, then correlate them to the damage suffered by LAB cells during the spray-drying process. The particularities of spray drying that might cause LAB cell death are detailed in this review, and the conclusion may enhance future studies on ways to improve cell viability.

Effect of Three Polysaccharides (Inulin, and Mucilage from Chia and Flax Seeds) on the Survival of Probiotic Bacteria Encapsulated by Spray Drying

Chia seed mucilage (CM), flaxseed mucilage (FM), and inulin (INL) were used as encapsulating agents to evaluate the possibility of increasing the survival of Lactobacillus casei var. rhamnosus, renamed recently to Lacticaseibacillus rhamnosus, after spray drying. Moreover, the viability of encapsulated L. rhamnosus was determined during the 250 day storage period at 4 °C. In a second stage, the conditions that maximized the survival of L. rhamnosus were evaluated on other probiotic bacteria (Lactiplantibacillus plantarum, Bifidobacterium infantis, and Bifidobacterium longum). Additionally, the viability of encapsulated probiotics during the 60 day storage period at 4 and 25 °C was evaluated. The conditions that maximize the survival of L. rhamnosus (90%) predicted by a face-centered central composite design were 14.4% w/v of maltodextrin, 0.6% w/v of CM, and 90 °C of inlet air temperature. Additionally, under these encapsulating conditions, the survival of L. plantarum, B. infantis, and B. longum was 95%, 97%, and 96%, respectively. The probiotic viability improved during storage at 4 °C but decreased at 25 °C. The highest viability values obtained for probiotics during spray drying and during storage suggest a thermoprotector effect of CM, which would ensure an optimal probiotic efficacy in the product, thus promoting its utilization in the food industry.