Spray Drying for Improved Viability of Probiotics

Electrospray drying of anaerobic bacteria into a stable powder for animal feed applications, using low heat and controlled atmosphere conditions to preserve viability and stability of the microorganisms. The method involves preparing a bacterial culture, forming a slurry with a carrier, applying an electrostatic charge, atomizing the slurry, and drying the droplets in a controlled atmosphere chamber. The resulting powder contains encapsulated bacteria with less than 15% moisture content, suitable for use in animal feed to prevent lactic acidosis and promote digestive health.

Source

Rapid temperature-controlled drying of particles using a novel atomization system that enables the simultaneous mixing and dehydration of particles at lower temperatures than conventional methods. The system comprises a nozzle device with three channels: an inner channel, a middle annular channel, and an outer annular channel. The middle annular channel features a gap width sufficient to atomize liquid suspensions, while the outer annular channel provides additional drying gas flow. The system operates at temperatures between 15°C and 35°C, with controlled drying gas flow rates and precise temperature control. This approach enables the formation of dry particle aerosols with reduced particle aggregation and minimal thermal damage, while maintaining high biological activity and therapeutic efficacy.

Source

Spray-dried biotherapeutic matrix compositions comprising a bacterial preparation, designed for direct inhalation delivery, offer a novel approach to treating respiratory diseases. The compositions contain a matrix of biotherapeutic constituents, including bacterial preparations, that can be produced through spray drying. The matrix composition is formulated for inhalation delivery, with the bacterial preparation maintaining viability and efficacy during the inhalation process. The compositions can be used in dry powder inhalers (DPIs) and metered dose inhalers (MDIs), providing a reliable and efficient delivery method for biotherapeutics.

Source

Probiotics have gained significant attention owing to their roles in regulating human health. Recently, spray drying has been considered as a promising technique to produce probiotic powders due to its advantages of high efficiency, cost-saving, and good powder properties. However, the severe environmental conditions from drying and digestion can significantly reduce cell viability, resulting in poor bioaccessibility and bioavailability of live cells. Therefore, there is a need to develop effective targeted delivery systems using spray drying to protect bacteria and to maintain their physiological functions in the targeted sites. This review highlights recent studies about spray-dried targeted delivery vehicles for probiotics, focusing on key strategies to protect bacteria when encountering external stresses, the formation mechanism of particles, the targeted release and colonization mechanisms of live cells in particles with different structures. Advances in the targeted delivery of live probiotics via spray-dried vehicles are still in their early stages. To increase the possibiliti... Read More

Source

Nano-scale probiotic microcapsules prepared by low-temperature ultrasonic atomization technology, comprising a method of injecting a low-temperature treated probiotic suspension into a surface acoustic wave atomizer to produce nano-droplets encapsulating the probiotics. The microcapsules exhibit improved bioavailability, stability, and targeting properties, enabling precise delivery of probiotics to the gastrointestinal tract and lungs for enhanced therapeutic effects.

Source

Shelf-stable, heat-treated beverage containing encapsulated probiotics that can be stored at ambient temperatures for extended periods without spoilage. The beverage contains microparticles with live probiotics encapsulated within. The microparticles are made by coating a core of sub-microparticles containing the probiotics with denatured protein using a fluidized bed process. This prevents leakage and degradation of the probiotics during heat treatment and storage. The encapsulated probiotics survive UHT processing and maintain viability for 24 months at room temperature.

Source

Microencapsulated microbial cultures with enhanced storage stability at elevated temperatures, comprising a microbial culture entrapped in a coacervate comprising a non-homogeneous encapsulation matrix with a high ratio of matrix material to core material, wherein the matrix material includes carbohydrates, proteins, and antioxidants. The microencapsulated cultures exhibit preserved viability over extended periods of storage at temperatures up to 37°C, enabling applications in products where refrigerated storage is not feasible.

Source

A probiotic granule comprising a core of probiotic bacteria coated with a single continuous layer of a hydrophobic solid dispersion containing a water-soluble polymeric stress absorber. The stress absorber is dispersed within a hydrophobic solid component such as fat, wax, or fatty acid, and provides mechanical protection and controlled dissolution of the granule. The granule enables prolonged survival of the probiotics during storage and passage through the gastrointestinal tract, and can be used in a variety of food products.

Source

Encapsulating probiotics using calcium carbonate to improve intestinal reach, stability during freeze-drying, and storage stability. The method involves encapsulating probiotics with calcium carbonate, freeze-drying the encapsulated probiotics, and then powdering the resulting calcium carbonate-encapsulated probiotic powder. The calcium carbonate reacts with bile in the intestines, converting to hydroxyapatite, aiding probiotic survival. The encapsulation prevents degradation during stomach acid and freeze-drying.

Source

A probiotic microcapsule preparation method that produces uniform microcapsules with controlled particle size, high encapsulation efficiency, and resistance to gastric acids and high temperatures. The method involves coating probiotic bacteria with a hydroxypropyl methylcellulose solution containing a coating material, followed by lyophilization. The resulting microcapsules exhibit improved survival ratios and stability compared to conventional methods.

Source

A method for producing crosslinked dried microparticles containing encapsulated live microorganisms via a single-step spray-drying process. The method involves combining a microbial solution containing a crosslinkable polymer, protective agents, and microorganisms with a crosslinking agent solution, and then subjecting the combined solutions to spray-drying using a co-axial nozzle. The resulting microparticles have a crosslinked polymeric matrix that protects the encapsulated microorganisms from environmental stressors and acidic conditions, enabling targeted delivery to the human intestine.

Source

This work proposes a novel drying method suitable for probiotic bacteria, called flash freeze-drying (FFD), which consists of a cyclic variation in pressure (up-down) in a very short time and is applied during primary drying. The effects of three FFD temperatures (25 C, 15 C, and 3 C) on the bacterial survival and water activity of Lactobacillus acidophilus LA5 (LA), previously microencapsulated with calcium alginate and chitosan, were evaluated. The total process time was 900 min, which is 68.75% less than the usual freeze-drying (FD) time of 2880 min. After FFD, LA treated at 25 C reached a cell viability of 89.94%, which is 2.74% higher than that obtained by FD, as well as a water activity of 0.0522, which is 55% significantly lower than that observed using FD. Likewise, this freezing temperature showed 64.72% cell viability at the end of storage (28 days/20 C/34% relative humidity). With the experimental data, a useful mathematical model was developed to obtain the optimal FFD operating parameters to achieve the target water content in the final drying.

Source

A dry composition of lactic acid bacteria (LAB) with enhanced storage stability, comprising LAB cells and a synergistic stabilizer blend of oligofructans, maltodextrin, inulin, and/or pea fiber. The stabilizer blend provides cryoprotection, lyoprotection, and storage stability to the LAB cells, enabling long-term viability and shelf life. The composition is suitable for use in infant formulas, dietary supplements, and other food products.

Source

Encapsulation of microbial cultures, such as lactic acid bacteria, in a fat matrix to improve their stability and viability during storage and processing. The encapsulated cultures retain viability through pasteurization and subsequent storage at ambient temperature, enabling their direct addition to dairy products without refrigeration. The encapsulation matrix comprises one or more fat components with a melting point of at least 30°C, which protects the cells from heat and prevents post-acidification during storage.

Source

Spray drying is a key method for producing stable and viable probiotic powders for food and pharmaceutical applications. This study optimized spray drying parameters to maintain probiotic viability, including inlet temperature, feed rate, and protective agents. The findings revealed that microencapsulation with biopolymers, such as alginate and proteins, significantly enhances probiotic stability during spray drying. Recent innovations in encapsulating materials and combining spray drying with other preservation methods further improve probiotic efficacy. This research underscores the importance of refining spray drying techniques to enhance the effectiveness of probiotics. Future studies should optimize these methods and explore their applications in various food matrices to develop more effective functional foods and therapeutic formulations. Advancements in spray drying and encapsulation technologies offer promising opportunities for improving probiotic delivery in the food and pharmaceutical industries.

Source

Probiotics, live microorganisms touted for their health-promoting properties, face limitations in stability and delivery, hindering their widespread public outreach. This review examines the potential of spray drying, a microencapsulation technique, as a key solution to unlock the power of probiotics for public benefit. Spray drying techniques is being employed for probiotics after analysing their advantages and challenges in preserving viable cultures, enhancing shelf life, and enabling diverse delivery formats. Spray drying empowers the incorporation of probiotics into various food products, facilitates the development of convenient supplements, and paves the way for targeted delivery for specific health needs and for the betterment of human being. Furthermore, the potential drawbacks of spray drying, such as viability loss and allergenicity concerns, emphasizing the need for further research to refine methods and optimize formulations are need to be analysed while using for drying applications. By critically evaluating the current landscape and future directions, this review highl... Read More

Source

Spray drying is one of the most frequently used encapsulation techniques. The incorporation of different active compounds in small capsules contributes to their protection and stability. Applications of spray drying of food ingredients are constantly being developed for the food industry due to the simplicity, low cost, effectiveness, and versatility of this technique. Probiotics and other active compounds, such as enzymes, can be encapsulated by spray drying by combining various carrier materials, such as maltodextrins, gums, modified starch, or alginate. However, exposure to high temperatures can be injurious to the integrity of probiotic cells or enzyme activity and can cause irreversible changes. Approaches such as enhancing pre- and postspray drying steps are crucial to maintaining the integrity of these active compounds in the dried powders. This review focuses mainly on two major factors affecting the survival of probiotics and the activity of enzymes during spray drying, namely, the choice of carrier/wall material and drying temperature, bringing new light on how these influe... Read More

Source

The protective effect of solid fat on probiotics to reduce heat damage during spray drying was revealed in previous study. However, the direct dispersion of fresh cells in the thermo-protectants did not encapsulate the probiotics in the oil phase, but dispersed in the water phase. Therefore, this study aims to improve the protective effect of solid fat to probiotics during spray drying by encapsulating Lactobacillus rhamnosus GG (LGG) in double emulsion (W/O/W) containing solid fat. In addition, various prebiotics were added in W/O/W as wall materials, and their ability of improving the vitality of probiotics was evaluated by combining spray drying and re-culture. The results of fluorescence microscope and scanning electron microscope demonstrated the successful encapsulation of LGG in double emulsions during spray drying, which increased the survival rate from 43.23% to 65.16% while improved the integrity of the subcellular structure. In terms of prebiotic effects, the microcapsules of W/O/W + inulin showed the lowest water activity and higher glass transition temperature, leading t... Read More

Source

The process of drying probiotic bacteria to enhance their storage stability is important for the food industry. This study aimed to assess the efficacy of various drying techniques and food-grade protectants in preserving the viability of Bifidobacterium animalis subsp. lactis KMP H9-01 during drying and under prolonged storage conditions. Among the four protectants tested (skim milk, trehalose, sucrose, and maltodextrin), trehalose and skim milk at 5% (w/v) were selected for freeze- and spray-drying, each conducted at different temperatures. This evaluation encompasses survivability and the observation of the shelf life of probiotic powders. The results demonstrated that spray-drying at 160 C/80 C, with either skim milk or trehalose as a protectant, yielded the highest viable cell counts (>log 7 CFU/g) even after 6 months of storage at room temperature in the range of 2530 C, regardless of the use of vacuum and nonvacuum packaging. Notably, the calculated inactivation rate values (KRT) demonstrated remarkable stability, ranging from 5.36 102 to 5.82 102 day1. Furthermore,... Read More

Source

Drying technologies are often utilized to maximize microbial shelf-life stability of probiotics-based foods. However, these processes inadvertently induce stress on microorganisms and reduce probiotic viability. This work sought to develop suitable protection strategies to maintain viability of powdered probiotics in different foods. A formulation platform (set of pre-existing/initial formulation templates for application/adaptation to various products) consisting of six powder formulations was evaluated. Each template combination comprised a probiotic, at least one prebiotic and at least one coating material. The powder particles were small (d50: 4.92 0.09 m to 9.30 1.09 m) to ensure optimal incorporation in foods for desirable mouthfeel, while all powders were favorably moisture-stable (aw: 0.34 0.53) and less susceptible to moisture uptake than their unencapsulated counterpart. At least one species from the platform was able to satisfy the viability and/or functional requirements on various food matrices which thus demonstrated its utility in formulation development.

Source

The intake of probiotics offers various health benefits; however, their efficacy depends on the maintenance of viability during industrial processing and digestion. Probiotic viability can be compromised during encapsulation, freeze-drying, storage, and digestion, necessitating multiple coatings. This complicates production and raises costs. In this study, CaCO

Source

To improve the viability of probiotics during food storage and gastrointestinal digestion, this study developed solid microcapsules co-loaded with probiotics and wheat germ oil using W1/O/W2 emulsion pre-encapsulation, followed by spray drying (SD), freeze drying (FD) and spray freeze drying (SFD), respectively. The effects of drying methods and wall materials on the microstructure, physicochemical properties, storage stability, and gastrointestinal tolerability were highlighted. Firstly, all samples showed high encapsulation efficiency for probiotics (86%99.2%) and wheat germ oil (72%85%), low moisture content (2.8%5.3%) and hygroscopicity (6.3%11.6%), and wall materials exhibited structural stability during the drying process. The results of viable cell counts indicated that SFD caused more damage to bacterial cells than the other two drying methods, as evidenced by the total death of encapsulated probiotics within 90 days. In contrast, SD and FD encapsulated probiotics remained at 8.89.9 log CFU/g after 150 days of storage at 4 C and 25 C. Furthermore, the viability of prob... Read More

Source

Spray drying microencapsulation has emerged as a promising technique for producing highly active probiotic powders. The efficient delivery of live probiotics to their target site, particularly the intestinal tract, is crucial for their therapeutic effectiveness. This study aimed to investigate the intestinal-targeted delivery function of particles containing Lactobacillus rhamnosus GG, trehalose and Eudragit L100 (L100) under various thermal convective drying conditions. The particle drying history, component migration within particle, and the microstructures of the final particles were thoroughly analysed. Our findings demonstrate that temperature and flow rate significantly influence the migration behaviours of trehalose and L100 within the droplets, subsequently impacting the substance distribution on the surface of the final particles. Notably, higher temperatures and flow rates promote the deposition of L100 on the particle surface, leading to enhanced intestinal-targeted delivery function. Cells encapsulated in spray-dried powders containing L100 and produced at 160 C exhibit... Read More

Source

Common factors influencing the survival of microbes to spray drying include microbial intrinsic resistance, properties of the carrier, inlet and outlet temperatures, and rate of feeding. In this work, cheese whey was used as both a growth medium and a carrier for spray drying of Bifidobacterium animalis subsp. lactis INL1. The growth of the strain was favoured by acid conditions, reaching higher counts when pH was not controlled during fermentation and when pH was controlled at a constant value of 5.5, compared with 6.5. Powders containing ca. 9 log order (cfu/g) of B. lactis INL1 were obtained by direct spray drying of the culture coming out of the fermenter. No differences in survival to spray drying were observed in terms of fermentation conditions. However, fermentation conditions are considered to have influenced the strain's survival along the storage. Spray drying in acid conditions was detrimental to the survival along storage.

Source

Electrostatic spray drying of a living microorganism that allows for cost savings and/or improved process efficiency and/or improved stability of the final product. The drying includes providing a suspension, comprising a microorganism with an electrical surface charge and a formulation aid; applying an electrostatic charge to said suspension; forming droplets of said suspension; drying said droplets, thereby forming dried particles; and collecting the dried particles.

Source

AbstractChanges in the viability of probiotic cells during spray drying were tracked, by developing an inactivation model of Lactobacillus rhamnosus GG (LGG) and coupling the model to the drying kinetics of spray drying using Computational Fluid Dynamics simulation. Six inactivation models in the Arrhenius-equation form were developed using single droplet drying experiments with average drying rates of 0.0110.044 kg/kg/s; all gave reliable goodness-of-fit. In simulating spray drying process, the predicted moisture content of LGG-containing particles well followed experimental trends. However, only inactivation model 6, which incorporated droplet temperature, moisture content, rate of temperature change, and drying rate, accurately predicted the survival of LGG. Models 15 that incorporated fewer kinetics parameters with higher activation energy values underestimated the degree of inactivation. The findings highlighted the crucial effects of the rates of temperature and moisture content change on the inactivation of probiotics during rapid drying with average drying rates of 0.310.8... Read More

Source

Probiotic bacteria confer a range of health benefits and are a focus of a growing number of studies. One of the main issues is their stability during drying and storage, which is why techniques, such as fluid bed drying and coating or treatment with stress factors during culturing, are utilized. The methods of the evaluation of probiotic viability and quality are, however, lacking and we need a way of distinguishing between different subpopulations of probiotic bacteria. To address this issue, imaging flow cytometry (IFC) has been utilized to assess cells after simulated in vitro digestion of dried and coated preparations treated with pH stress and heat shock. Samples were analyzed fresh and after 12 months of storage using RedoxSensor green and propidium iodide dyes to assess metabolic activity and cell membrane integrity of the cells. The results were then used to design a drying process on an industrial scale and evaluate the economic factors in the SuperPro Designer v13 software. Based on the number of biologically active and beneficial cells obtained utilizing tested methods, th... Read More

Source

Microencapsulating lactic acid bacteria (LAB) cultures using complex coacervates containing octenyl succinic anhydride (OSA) starch and chitosan for improved storage stability at elevated temperatures. The microencapsulation process involves sequential addition of oppositely charged biopolymers to form a protective complex around the LAB. This shields the bacteria during drying and storage without refrigeration. The OSA starch and chitosan coacervates enhance viability retention compared to conventional encapsulation methods. The microencapsulated LAB cultures can be used in products like feed, food, beverages, and pharmaceuticals without refrigerated storage.

Source

Lactobacillus rhamnosus GG (LGG) is an acceptable probiotic strain that can live and grow at a gastrointestinal acidic pH and on a bile-rich medium. The influence of spray-drying microencapsulation of LGG on the physicochemical parameters and survivability was investigated in the present work. LGG was spray-dried with three different maltodextrin concentrations (6, 12, and 18% w/v). The inlet and outlet air temperatures of the spray-dryer were kept at 170 5C and 75 5C, respectively. The physicochemical parameters (moisture content (wet basis), water activity, and colour), viability (colony forming unit/g), and simulated gastrointestinal digestion were all investigated. Only 18% MD was selected on the basis of moisture content and log CFU/g. The total soluble solids (TSS) of 16.28 0.93 Brix were obtained using 18% MD. The end product had a moisture content of 5.40 0.20%, and a water activity of 0.32 0.02 aw, which were acceptable. The L*, a*, and b* of the final product were 95.14 0.19, -2.33 0.02, and 7.17 0.13, respectively. The spray-dried powder had final probio... Read More

Source

Spray drying (SD) is extensively used to encapsulate lactic acid bacteria in large-scale industrial applications; however, bacteria combat several harms that reduce their viability. In this study, a novel technique called electrostatic spray drying (ESD) was used to explore the benefits and disadvantages of using electrostatic charge and lower temperatures in the system. Freeze drying (FD) was used as a reference. The effect of different encapsulation agents, like maltodextrin, arabic gum, and skim milk, on the viability of Lacticaseibacillus rhamnosus GG (LGG) was investigated. The initial cell concentration, particle size distribution, aspect ratio, sphericity, scanning-electron-microscopy images, moisture content, water activity, glass transition, rehydration abilities, and survival during storage were compared. Skim milk was proven to be the best protectant for LGG, regardless of the drying process or storage time. A huge reduction in cell numbers (4.49 0.06 log CFU/g) was observed with maltodextrin using SD; meanwhile, it was protected with minimum loss (8.64 0.62 log CFU/g)... Read More

Source

Several lactic acid bacteria (LAB) species have been recognized as probiotics and are of considerable interest due to their potential ability to confer health benefits upon consumption. In the animal feed sector, probiotics offer an alternative to the use of antibiotic growth promoters. The preservation and incorporation of probiotics into dry products requires carefully meeting several criteria and overcoming technological challenges to maintain their functionality. Drying is a crucial step in the process, but the probiotic properties of the resulting powder and the final cell viability in the food product are significantly influenced by the type of protective compounds and drying techniques employed. In light of the growing demand for functional animal products, this review focuses on the damages incurred during microorganism dehydration processes for food incorporation, and explores strategies to minimize such damages. It provides an overview of the effects of probiotic products in the animal feed industry, including their incorporation in low-moisture food matrices and key consid... Read More

Source

A method for producing active compound powders using electrostatic spray drying at low temperatures, resulting in powders with improved shelf stability, loading capacity, and encapsulation efficiency compared to traditional spray drying methods. The method involves electrostatically charging droplets of a formulation containing the active compound, encapsulating agent, and optional excipients, and then drying them at inlet temperatures of 150°C or below and exhaust temperatures of 100°C or below.

Source

Formation of a microparticle comprising an active agent such as a probiotic encapsulated in a denatured plant protein matrix. The formation includes preparing a protein suspension comprising denatured plant protein; combining the protein suspension and active agent to form a mixture; treating the mixture to form a microparticle comprising active agent encapsulated in a denatured plant protein matrix, in which the treating step comprises polymerising the denatured plant protein matrix with a calcium salt or spray englobing on a fluidised bed dryer; and drying the microparticles.

Source

A method for preparing high-performance powders through a combination of spray drying, liquid nitrogen quick-freezing, and vacuum freeze-drying. The process enables the precise control of particle size and density, while maintaining the activity and viability of microorganisms like probiotics. The method employs a unique sequence of freeze-drying steps, where the microorganisms are first rapidly cooled to form a slurry, followed by liquid nitrogen quick-freezing to rapidly freeze the slurry, and finally vacuum freeze-drying to remove the remaining water content while preserving the microorganism's structural integrity. This approach enables the production of uniform, freeze-dried powders with controlled particle size and density, making them ideal for applications requiring precise powder characteristics.

Source

This study aimed to evaluate the survival of the probiotic Lactobacillus fermentum when it is encapsulated in powdered macroemulsions to develop a probiotic product with low water activity. For this purpose, the effect of the rotational speed of the rotor-stator and the spray-drying process was assessed on the microorganism survival and physical properties of probiotic high-oleic palm oil (HOPO) emulsions and powders. Two Box-Behnken experimental designs were carried out: in the first one, for the effect of the macro emulsification process, the numerical factors were the amount of HOPO, the velocity of the rotor-stator, and time, while the factors for the second one, the drying process, were the amount of HOPO, inoculum, and the inlet temperature. It was found that the droplet size (ADS) and polydispersity index (PdI) were influenced by HOPO concentration and time, -potential by HOPO concentration and velocity, and creaming index (CI) by speed and time of homogenization. Additionally, HOPO concentration affected bacterial survival; the viability was between 78-99% after emulsion pre... Read More

Source

Spray-dried compositions for delivering probiotics in food products, comprising a prebiotic, a probiotic, and a coating material, that improve probiotic viability and functionality through a novel encapsulation strategy. The compositions are prepared by spray drying a solution containing the prebiotic, probiotic, and coating material, and can be incorporated into various food matrices to enhance probiotic delivery.

Source

Probiotics and prebiotics are of great interest to the food and pharmaceutical industries due to their health benefits. Probiotics are live bacteria that can confer beneficial effects on human and animal wellbeing, while prebiotics are types of nutrients that feed the beneficial gut bacteria. Powder probiotics have gained popularity due to the ease and practicality of their ingestion and incorporation into the diet as a food supplement. However, the drying process interferes with cell viability since high temperatures inactivate probiotic bacteria. In this context, this study aimed to present all the steps involved in the production and physicochemical characterization of a spray-dried probiotic and evaluate the influence of the protectants (simulated skim milk and inulin:maltodextrin association) and drying temperatures in increasing the powder yield and cell viability. The results showed that the simulated skim milk promoted higher probiotic viability at 80 C. With this protectant, the probiotic viability, moisture content, and water activity (Aw) reduce as long as the inlet tempe... Read More

Source

A non-dairy probiotic composition in the form of a soluble powder based on citrus juice or juice, incorporating biomass of a probiotic microorganism of the genus Bacillus and at least two prebiotic agents. The composition is produced by spray drying a mixture of juice, prebiotics, and Bacillus biomass, and is suitable for preventing and treating gastrointestinal conditions such as acute diarrheal disease and stabilizing the gastrointestinal flora after antibiotic treatments.

Source

The administration of living microorganisms is of special interest, with regard to probiotic microorganisms providing health benefits to the patient. Effective dosage forms require the preservation of microbial viability until administration. Storage stability can be improved by drying, and the tablet is an especially attractive final solid dosage form due to its ease of administration and its good patient compliance. In this study, drying of the yeast Saccharomyces cerevisiae via fluidized bed spray granulation is investigated, as the probiotic Saccharomyces boulardii is a variety of it. Fluidized bed granulation enables faster drying than lyophilization on the one hand and lower temperatures than spray drying on the other hand, which are the two predominantly used techniques for life-sustaining drying of microorganisms. Yeast cell suspensions enriched with protective additives were sprayed onto the carrier particles of common tableting excipients, namely, dicalcium phosphate (DCP), lactose (LAC) and microcrystalline cellulose (MCC). Different protectants, such as mono-, di-, oligo-... Read More

Source

Drying is broadly used to enhance the stability of thermosensitive biologics (for example proteins, probiotics) despite the risk of inadequate product quality after the drying process. Continuous fluidized bed drying is an attractive technology for these active pharmaceutical ingredients owing to the short mean residence time at elevated temperatures, compared to batch-type drying technologies and the possibility to closely monitor and precisely control the process. In this work, an integrated continuous granulation drying milling line was used to manufacture granules ready for tableting from a suspension of probiotic bacteria. A mechanistic drying model suitable to predict the product temperature in the dryer and the moisture content of the granules was built. This allowed finding the optimal operating conditions for maximal bacteria load and low residual moisture content in the product, which has the potential to enable direct integration with the tableting unit. A continuous experiment was carried out with the in silico - optimized process parameters. The produced granules had... Read More

Source

Recently, there has been a growing interest in producing functional foods containing encapsulated probiotic bacteria due to their positive effects on human health. According to their perceived health benefits, probiotics have been incorporated into a range of dairy products, but the current major challenge is to market new, multicomponent probiotic foods and supplements. Nevertheless, only a few products containing encapsulated probiotic cells can be found as non-refrigerated products. In this work, spray drying technology was investigated in order to produce an innovative nutraceutical formulation based on lactic acid bacteria (LAB), and was able to ensure a good storage stability of probiotics (no less than 109 CFU/cps) in non-refrigerated conditions. Probiotic-loaded microparticles from spray drying experiments were produced under different conditions and compared by thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and the enumeration of the number of viable cells in order to identify the formulation exhibiting the most promising characteristics. Results from ... Read More

Source

Experimental desing employed to identify the best conditions to obtained a spray dried powder containing probiotics and prebiotics.

Source

The previous study revealed the protective effect of solid fat on probiotics against heat damage during spray drying. However, the simple mixing mode prior to spray drying did not effectively enhance the cooling efficiency of solid fat on probiotics. Therefore, this study aimed to improve the encapsulation efficiency of solid fat for probiotics and reduce the exposure area of probiotics to hot air during spray drying by encapsulating them in coacervates formed by whey protein isolate-high melting point fat shortening oil (SO) and gum arabic through complex coacervation. The combination of fluorescence microscope and scanning electron microscope proved that the coacervates successfully encapsulated the probiotics during spray drying, resulting in an increased survival rate from 24.59% to 54.96% after the process. Differential scanning calorimetry and single droplet drying experiments confirmed that the addition of SO reduced the temperature of microcapsules by increasing the enthalpy of melting during spray drying, without affecting the drying rate. Among the tested formulations, the ... Read More

Source

Abstract Functional food products containing viable probiotics have become increasingly popular and demand for probiotic ingredients that maintain viability and stability during processing, storage, and gastrointestinal digestions. This has resulted in heightened research and development of powdered probiotic ingredients. The aim of this review is to overview the development of dried probiotics from upstream identification to downstream applications in food. Free probiotic bacteria are susceptible to various environmental stresses during food processing, storage, and after ingestion, necessitating additional materials and processes to preserve their activity for delivery to the colon. Various classic and emerging thermal and nonthermal drying technologies are discussed for their efficiency in preparing dehydrated probiotics, and strategies for enhancing probiotic survival after dehydration are highlighted. Both the formulation and drying technology can influence the microbiological and physical properties of powdered probiotics that are to be characterized comprehensively with variou... Read More

Source

Lactic acid bacteria (LAB) are well known for the production of fermented foods and their beneficial effects on consumers.However, they are very sensitive to environmental conditions, and their viability and functionality can be affected during different processing methods and storage.Therefore, encapsulation is essential to avoid injuries to bacterial cells and improve their survivability.Freeze-drying and spraydrying are two commonly used drying techniques for microencapsulation.Freeze-drying has been the conventional drying process for encapsulation and production of bacterial cultures in dried form, but it has some limits, such as low production yield and longer drying time.On the other hand, spray-drying technique has benefits such as fast, higher, and continuous productivity.Nowadays, due to increasing urbanization and consumer awareness, the beneficial LAB is dried in various food matrices apart from dairy food to produce functional food powders in ready-to-reconstitute form.These products have beneficial effects on live microbes as well as nutritional and functional propertie... Read More

Source

Probiotic microorganisms provide health benefits to the patient when administered in a viable form and in sufficient doses. To ensure this, dry dosage forms are preferred, with tablets in particular being favored due to several advantages. However, the microorganisms must first be dried as gently as possible. Here, the model organism Saccharomyces cerevisiae was dried by spray drying. Various additives were tested for their ability to improve yeast cell survival during drying. In addition, the influence of various process parameters such as inlet temperature, outlet temperature, spray rate, spray pressure and nozzle diameter was investigated. It was possible to dry the yeast cells in such a way that a substantial proportion of living microorganisms was recovered after reconstitution. Systematic variation of formulation and process parameters showed that the use of protective additives is essential and that the outlet temperature determines the survival rate. The subsequent compression of the spray-dried yeast reduced viability and survival could hardly be improved by the addition of ... Read More

Source

Abstract The objective of this research was to encapsulate probiotic bacteria based on the protein matrix and investigate the influences on the survival of probiotic bacteria during spray drying, in vitro gastrointestinal digestion, heating, and storage. A probiotic isolate Bacillus coagulans BC01 was spray dried in whey protein isolate (WPI), soy protein isolate (SPI), camel whey protein isolate, or sodium caseinate. Probiotic microcapsules fabricated using WPI obtained the highest survival during spray drying, NaCl and paraxin challenges and storage, as less cell wall damage occurred during spray drying which could be observed by flow cytometer. However, the highest survivals during in vitro gastrointestinal digestion and thermal treatment were found in microcapsules with SPI matrix, which could be attributed to its relatively low solubility in water that prevented probiotics from being released prematurely, thus protecting probiotics from the damage of low pH environment and diminishing the direct contact of cells with external heat shock. In conclusion, the current study demonstr... Read More

Source

Over the last 15 years, spray drying (SD), as an alternative to lyophilization, to manufacture and increase the stability of biologics has demonstrated promising outcomes. Pharmaceutical companies, on the other hand, have yet to expand technology for the production of aseptic spray-dried biologics. In this mini-review, we have discussed the limitations and potential of SD in biologics production.

Source

Probiotics are susceptible to factors such as stomach acid, enzymes, and bile salts. Also, when incorporated into food matrices, intrinsic or processing factors like low pH, high water activity, or high cooking temperatures can negatively affect the viability of microorganisms. Encapsulation technology can ensure the safe delivery of probiotics to the gut and better survival during processing and storage. Several techniques are used to protect probiotics, for example, emulsion, extrusion, spray-drying, freeze-drying, liposome, electrospinning, and others. Here, we describe in detail the main methods of encapsulation of probiotics, including emulsion, extrusion, and spray-drying techniques.

Source

To promote the adequate supplementation of probiotics and bioactives in food formulations, this study aimed to develop synbiotic co-microcapsules containing probiotic strain Lactococcus lactis SKL 13 and bioactive compound, namely -Aminobutyric acid (GABA), using spray (at the air inlet and outlet temperatures of 110 2 C and 50 5 C, respectively, with a feed flow rate of 2.5 mL min1) and freeze-drying (at - 40 C temperature, 1 mbar pressure for 12 h) in a ternary exopolysaccharide (such as maltodextrin, dextran, and inulin in a combination of 8.41, 4.59, and 0.40 g/100 mL, respectively) matrix. The freeze-drying resulted in higher probiotic and GABA encapsulation efficiencies of 95.08 and 90.04%, respectively, than spray drying (probiotics: 93.12% and GABA: 83.46%). The absence of diffraction peaks indicated an amorphous metastable state of microcapsules. Only 1% reduction in probiotic count and 5% decrease in GABA content were observed in dried capsules after 60 days of storage as well as both the powders showed non-significant (p > 0.05) reduction in probiotic count (2.9... Read More

Source