Advances in Microencapsulation of Flavor Substances: Preparation Techniques, Wall Material Selection, Characterization Methods, and Applications

This review systematically examines advances in flavor microencapsulation technology from 2014 to 2024, focusing on innovations in preparation techniques, trends in wall material selection, and characterization methods. Literature metrological analysis shows that spray drying is the predominant technology (25% of reports); its shortcomings in volatile flavor retention have driven improved strategies such as vacuum low-temperature drying, ultrasound assistance, and monodisperse atomization. Emerging technologies such as electrohydrodynamic methods (electrospinning/electrospraying) and supercritical fluid processing are favored due to their nonthermal advantages. Overall, traditional polysaccharides have been widely used due to their good emulsifying and stabilizing properties. In the meanwhile, plant-based polysaccharides (e.g., inulin, hemicellulose) and proteins (e.g., pea protein) are increasingly preferred as the wall materials driven by sustainability and clean-labeling requirements. Morphological analysis and particle size and distribution studies have highlighted the key role of microstructure in stability and release kinetics, with multicore and multishell structures optimizing controlled release performance. Despite progress, gaps remain in the standardized assessment of encapsulation efficacy, the cost-effectiveness of novel materials, and practical food applications. In the future, a combination of interdisciplinary approaches is needed to investigate low-energy preparation technologies, functionalized wall materials, and intelligent release mechanisms to achieve the better application of flavor microencapsulates in food.

Structures and compositions of the oil/wall interfaces and wall layers affected the properties of spray-dried fish oil powders

Herein, 12 types of fish oil emulsions were used to prepare 12 types of spray-dried fish oil powders with three gelatins (positive fish gelatin, positive porcine skin gelatin, and negative bovine skin gelatin), two negative pectins (high and low methoxy pectin), and negative sodium starch octenyl succinate (SSOS). The powders consisted of microscale capsules with bi- or monolayer oil/wall interfaces, and monolayer wall layers. SSOS significantly decreased the bulk and tapped densities of the powders. All powders had low water activities (0.14-0.26). Gelatin/pectin and gelatin/pectin/SSOS powders had encapsulation efficiencies of 45.1 %-75.9 % and 70.1 %-93.0 %, respectively. The oxidative stability depended on the compositions of the powder wall layers. FG+/LMP/SSOS wall layer induced the lowest PV peak value (325 ± 15 mmol/kg oil). BSG-/HMP/SSOS wall layer induced the highest PV peak value (1273 ± 49 mmol/kg oil). The free fatty acid release percentages in the in vitro digestion system depended on the structures and compositions of oil/wall interfaces. FG+@LMP/SSOS interface induced the lowest FFA release percentage (33.9 % ± 1.7 %) and BSG-/HMP interface induced the highest FFA release (79.3 % ± 8.1 %). The results suggested useful information on the effect of oil/wall interfaces and wall layers on the preparation and properties of fish oil powders.

Optimizing n-3 PUFA dietary enrichment in slow-growing Korat chickens using lipid-based nanoparticles: Effects on growth performance, carcass traits, meat quality, meat fatty acid composition, and blood biochemical parameters

This research aimed to investigate the optimization of lipid-based nanoparticles to improve the utilization of n-3 PUFA source in chicken diets. Three groups of slow-growing Korat chickens were reared under the same conditions and fed a diet containing 6 % rice bran oil (RBO, control group), 3 % tuna oil (3 % TO) and 3 % tuna oil in targeted lipid-based nanoparticles (3 % TO-TNP). The growth performance, carcass composition, meat quality, fatty acid profile of breast and thigh meat, hematological and plasma biochemical parameters were evaluated. The dietary lipid source had no effect on the growth performance, carcass composition, or breast and thigh meat quality (P > 0.05). Compared to the control group, the 3 % TO and 3 % TO-TNP groups exhibited lower levels of C18:2n-6 (linoleic acid) and n-6 PUFA (P < 0.05). There was no significant difference between groups in the C18:3n-3 (ALA) level in breast and thigh meat, whereas the levels of C20:5n-3 (EPA) and C22:6n-3 (DHA) were higher in both TO groups. However, due to the high temperature required during the drying step of the nanoparticle synthesis process, n-3 PUFA enrichment was more efficient when TO was directly incorporated into the diet than when using targeted nanoparticles. Nevertheless, there was no difference between the 3 % TO and 3 % TO-TNP groups in the n-6/n-3 ratio (P > 0.05). The hemoglobin and hematocrit values were higher in 3 % TO-TNP than in the other groups (P < 0.05). In the plasma, HDL level was reduced in the TO groups compared to the control group (P < 0.05) suggesting a lower cholesterol hepatic synthesis and export. The TO groups had a higher activity of alanine amino transferase but a lower creatinine content than the control group (P < 0.05). The uric acid content was higher in 3 % TO-TNP group than in the 3 % TO group (P < 0.05) but no different compared with the control group. However, the values obtained for the hematological and biochemistry parameters measured in blood and plasma were within the normal range for chickens. To conclude, the supplementation of lipid-based nanoparticles allowed for change the fatty acid composition of chicken meat without any negative effect on production and health status of chickens.

Effects of Different Drying Methods on Physicochemical Properties and Nutritional Quality of Abalone Bioactive Peptides

This study conducted a systematic comparison of four drying methods (vacuum freeze-drying, spray drying, spray freeze-drying, and hot air drying) on abalone bioactive peptides, investigating their effects on physicochemical properties and nutritional composition. Scanning electron microscopy revealed distinct morphological characteristics: hot-air-dried samples showed compact structures with large particles, and vacuum-freeze-dried samples exhibited flaky morphology, while spray-freeze-dried and spray-dried samples demonstrated advantageous smaller particle sizes. Spray freeze-drying achieved superior emulsification capacity and fat absorption, significantly higher than hot air drying. The enhanced performance was attributed to increased exposure of hydrophobic amino acid residues and improved surface activity. Regarding nutritional composition, vacuum freeze-drying demonstrated optimal protein and total amino acid preservation, while spray freeze-drying showed the highest retention of Ca and Fe. Interestingly, hot air drying exhibited superior vitamin A retention, attributed to its fat-soluble nature and stability below 100 °C. The particle size reduction in spray-freeze-dried samples enhanced solvent-solute contact area, contributing to improved solubility and consequently superior foaming properties. These findings provide valuable insights into the relationship between drying methods and product characteristics, offering guidance for optimizing processing conditions in marine protein production.

Impact of wall materials and DHA sources on the release, digestion and absorption of DHA microcapsules: Advancements, challenges and future directions

Docosahexaenoic acid (DHA), an essential omega-3 fatty acid, offers significant health benefits but faces challenges such as distinct odor, oxidation susceptibility, and limited intestinal permeability, hindering its broad application. Microencapsulation, widely employed, enhances DHA performance by facilitating controlled release, digestion, and absorption in the gastrointestinal tract. Despite extensive studies on DHA microcapsules and related delivery systems, understanding the mechanisms governing encapsulated DHA release, digestion, and absorption, particularly regarding the influence of wall materials and DHA sources, remains limited. This review starts with an overview of current techniques commonly applied for DHA microencapsulation. It then proceeds to outline up-to-date advances in the release, digestion and absorption of DHA microcapsules, highlighting the roles of wall materials and DHA sources. Importantly, it proposes strategies for overcoming challenges and exploiting opportunities to enhance the bioavailability of DHA microcapsules. Notably, spray drying dominates DHA microencapsulation (over 90 % usage), while complex coacervation shows promise for future applications. The combination of proteins and carbohydrates or phospholipids as wall material exhibits potential in controlling release and digestion of DHA microcapsules. The source of DHA, particularly algal oil, demonstrates higher lipid digestibility and absorptivity of free fatty acids (FFAs) than fish oil. Future advancements in DHA microcapsule development include formulation redesign (e.g., using plant proteins as wall material and algal oil as DHA source), technique optimization (such as co-microencapsulation and pre-digestion), and creation of advanced in vitro systems for assessing DHA digestion and absorption kinetics.

New perspective on protein-based microcapsules as delivery vehicles for sensitive substances: A review

Sensitive substances have attracted wide attention due to their rich functional activities, such as antibiosis activities, antioxidant activities and prevent disease, etc. However, the low stability of sensitive substances limits their bioavailability and functional activities. Protein-based microcapsules can encapsulate sensitive substances to improve their adverse properties due to their good stability, strong emulsifying ability and wide source. Therefore, it is necessary to fully elaborate and summarize protein-based microcapsules to maximize their potential benefits in nutritional interventions. The focus of this review is to highlight the classification of protein-based microcapsules. In addition, the principles, advantages and disadvantages of preparation methods for protein-based microcapsules are summarized. Some novel preparation methods for protein-based microcapsules are also emphasized. Moreover, the mechanism of protein-based microcapsules that release sensitive substances in vitro is elucidated and summarized. Furthermore, the applications of protein-based microcapsules are outlined. Protein-based microcapsules can effectively encapsulate sensitive substances, which improve their bioavailability, and provide protective effects during storage and gastrointestinal digestion. In addition, microcapsules can improve the sensory quality of food and enhance its stability. The performance of protein-based microcapsules for delivering sensitive substances is influenced by factors such as protein type, the ratio between protein ratio and the other wall material, the preparation process, etc. Future research should focus on the new composite protein-based microcapsule delivery system, which can be applied to in vivo research and have synergistic effects and precise nutritional functions. In summary, protein-based microcapsules have broader research prospects in the functional foods and nutrition field.

Microencapsulation of fish oil by spray drying, spray freeze-drying, freeze-drying, and microwave freeze-drying: Microcapsule characterization and storage stability

The objective of this paper was to evaluate the effect of spray drying (SD), spray freeze-drying (SFD), freeze-drying (FD), and microwave freeze-drying (MFD) on the characteristics of fish oil (FO) microcapsules. The physicochemical properties, morphology, fatty acid composition, and stability of the microcapsules were analyzed. The encapsulation efficiencies of microcapsules dried by SD, SFD, FD, and MFD were 86.98%, 77.79%, 63.29%, and 57.89%, respectively. SD microcapsules exhibited superior properties in terms of effective loading capacity, color, and flowability. Conversely, SFD microcapsules demonstrated improved solubility. Microencapsulation positively affected the thermal stability of FO, but the content of unsaturated fatty acids decreased. The findings from the storage experiment indicated that the oxidative stability of SD fish oil microcapsules was marginally lower compared to microcapsules produced through three alternative drying techniques, all of which were based on the FD concept. The comparison of various drying methods and their effects on the quality of FO microcapsules offers valuable insights that can serve as a foundation for the industrial production of high-quality microcapsules.

Exploring conventional and emerging dehydration technologies for slurry/liquid food matrices and their impact on porosity of powders: A comprehensive review

The contribution of dehydration to the growing market of food powders from slurry/liquid matrices is inevitable. To overcome the challenges posed by conventional drying technologies, several innovative approaches have emerged. However, industrial implementation is limited due to insufficient information on the best-suited drying technologies for targeted products. Therefore, this review aimed to compare various conventional and emerging dehydration technologies (such as active freeze, supercritical, agitated thin-film, and vortex chamber drying) based on their fundamental principles, potential applications, and limitations. Additionally, this article reviewed the effects of drying technologies on porosity, which greatly influence the solubility, rehydration, and stability of powder. The comparison between different drying technologies enables informed decision-making in selecting the appropriate one. It was found that active freeze drying is effective in producing free-flowing powders, unlike conventional freeze drying. Vortex chamber drying could be considered a viable alternative to spray drying, requiring a compact chamber than the large tower needed for spray drying. Freeze-dried, spray freeze-dried, and foam mat-dried powders exhibit higher porosity than spray-dried ones, whereas supercritical drying produces nano-porous interconnected powders. Notably, several factors like glass transition temperature, drying technologies, particle aggregation, agglomeration, and sintering impact powder porosity. However, some binders, such as maltodextrin, sucrose, and lactose, could be applied in controlled agglomeration to enhance powder porosity. Further investigation on the effect of emerging technologies on powder properties and their commercial feasibility is required to discover their potential in liquid drying. Moreover, utilizing clean-label drying ingredients like dietary fibers, derived from agricultural waste, presents promising opportunities.

Research progress of starch as microencapsulated wall material

Starch is non-toxic, low cost, and possesses good biocompatibility and biodegradability. As a natural polymer material, starch is an ideal choice for microcapsule wall materials. Starch-based microcapsules have a wide range of applications and application prospects in fields such as food, pharmaceuticals, cosmetics, and others. This paper firstly reviews the commonly used wall materials and preparation methods of starch-based microcapsules. Then the effect of starch wall materials on microcapsule properties is introduced in detail. It is expected to provide researchers with design inspiration and ideas for the development of starch-based microcapsules. Next the applications of starch-based microcapsules in various fields are presented. Finally, the future trends of starch-based microcapsules are discussed. Molecular simulation, green chemistry, and solutions to the main problems faced by resistant starch microcapsules may be the future research trends of starch-based microcapsules.

Strategies for improving loading of emulsion-based functional oil powder

Functional oil is type of oil that is beneficial to human health and has nutritional value, however, functional oils are rich in bioactive substances such as polyunsaturated fatty acids which are sensitive to environmental factors and are susceptible to oxidation or decomposition. Construction of emulsion-based oil powder is a promising approach for improving the stability and solubility of functional oils. However, the low effective loading of oil in powder is the main challenge limiting encapsulation technology. This manuscript focuses on reviewing the current research progress of emulsion-based functional oil powder construction and systematically summarizes the processing characteristics of emulsion-based oil powder with high payload and summarizing the strategies to enhance the payload of powder in term of emulsification and drying, respectively. The impact of emulsion formation on oil powder production is discussed from different characteristics of emulsions, including emulsion composition, emulsification methods and emulsion types. In addition, the current status of improving material loading performance by various modifications to the drying technology is discussed, including the addition of drying processing additives, changes in drying parameters and the effect of innovative technological means.

Combination of α-lactalbumin and gum Arabic for microencapsulation of L-menthol: The effects on flavor release during storage and rehydration

L-menthol-containing food products generally show the flavor loss during storage due to their high volatility. The hydrophobicity of L-menthol also causes the inadequate flavor release during rehydration. In this study, the stability of L-menthol was enhanced by microencapsulation and the effect of different powder drying techniques was also investigated. The highest efficiency (76.58-78.66 %) and loading content (18.58-28.35 mg/g) of encapsulations were obtained by using a mass ratio of 2:1(α-LA: GA). Then they were dried by non-thermal spray freeze drying (SFD) technique compared to spray drying (SD) and freeze-drying (FD) process. The SFD particles were shown to be spherical and porous with the highest porosity (86.82 %). α-LA/GA based microparticles with spherical shapes were demonstrated to largely enhance flavor retention during high humidity storage. In addition, the porous structures of SFD powders could cause rapid rehydration in liquid models, and the release behaviors of loaded L-menthol followed the Fickian diffusion. Consequently, the SFD technique shows great potential to produce microparticles by regulating the release behaviors of L-menthol during storage and rehydration.

Stirred Yogurt as a Delivery Matrix for Freeze-Dried Microcapsules of Synbiotic EVOO Nanoemulsion and Nanocomposite

Nowadays, dairy products are considered a good matrix to deliver many functional substances either vital oils or probiotic cells. Two models of microcapsules were produced from co-encapsulation of extra virgin olive oil (EVOO) nanoemulsion or nanocomposite and synbiotic bacteria (maltodextrin with Lactobacillus acidophilus and Bifidobacterium bifidum) using the freeze-drying technique. These models of microcapsules were added to stirred yogurt, and then its storage effect on microbiology, chemically, and sensory properties were evaluated for 21 days. The average droplet size and zeta potential distribution of EVOO nanoemulsion and nanocomposite were investigated. Also, oxidative stability, microencapsulation efficiency, release profile, and antioxidant activity were studied. The results showed that the average particle size of EVOO nanoemulsion and nanocomposite ranged between 416 and 475 nm, while zeta potential was -39.6 and -33.6 mV, respectively. The induction period of EVOO extracted from nanoemulsion and nanocomposite microcapsules models was 11.30 and 8 h. The microencapsulation efficiency of probiotic and EVOO was determined at 88.84 and 65.61% for the nanoemulsion microcapsules model, while the nanocomposite microcapsules model showed 98.49 and 72%. The two models of microcapsules have boosted the viability of probiotic bacteria inside stirred yogurt than free cells. Also, the presence of microcapsules did not affect the viability of stirred yogurt starter cultures, and high values for the total solid and protein were detected. Therefore, the results recommended that stirred yogurt is a good delivery carrier for highly antioxidant and healthy microcapsules of synbiotic EVOO nanoemulsion and nanocomposite.

Microencapsulation of Essential Oils by Spray-Drying and Influencing Factors

Essential oils (EOs) are known as any aromatic oily organic substances which are naturally synthesized in plants. Exhibiting a broad range of biological activities, EOs have played a key role in numerous industries for ages, including pharmaceutical, textile, and food. However, the volatility and high sensitivity to environmental influences pose challenges to the application of EOs on industrial scale. Microencapsulation via the spray-drying method is one of the promising techniques to overcome these challenges, thanks to the presence of wall materials that properly protect the core EOs from oxidation and evaporation. By optimization of key factors related to the infeed emulsion properties and spray-drying process, the encapsulation efficiency and retention of encapsulated EOs could be significantly improved, thus allowing a wide range of EO applications. This review attempts to discuss on different determining factors of the spray-drying process to develop an effective encapsulation formula for EOs. Furthermore, recent applications of encapsulated EOs in the fields of foods, pharmaceuticals, and textile industries are also thoroughly addressed.

Microparticle encapsulation of a tuberculosis subunit vaccine candidate containing a nanoemulsion adjuvant via spray drying

Spray drying is a technique that can be used to stabilize biopharmaceuticals, such as vaccines, within dry particles. Compared to liquid pharmaceutical products, dry powder has the potential to reduce costs associated with refrigerated storage and transportation. In this study, spray drying was investigated for processing an adjuvanted tuberculosis subunit vaccine, formulated as an oil-in-water nanoemulsion, into a dry powder composed of microparticles. Applying in-silico approaches to the development of formulation and processing conditions, successful encapsulation of the adjuvanted vaccine within amorphous microparticles was achieved in only one iteration, with high retention (>90%) of both the antigen and adjuvant system. Moisture-controlled stability studies on the powder were conducted over 26 months at temperatures up to 40 °C. Results showed that the powder was physically stable after 26 months of storage for all tested temperatures. Adjuvant system integrity was maintained at temperatures up to 25 °C after 26 months and after one month of storage at 40 °C. The spray-dried product demonstrated improved antigen thermostability when stored above refrigerated temperatures as compared to the liquid product. These results demonstrate the feasibility of spray drying as a method of encapsulating and stabilizing an adjuvanted vaccine.

Amelioration of the stability of polyunsaturated fatty acids and bioactive enriched vegetable oil: blending, encapsulation, and its application

Lipid oxidation in vegetable oils is the primary concern for food technologists. Modification of oils like hydrogenation, fractionation, inter-esterification, and blending are followed to improve nutritional quality. Blending non-conventional/conventional vegetable oils to obtain a synergistic oil mixture is commonly practiced in the food industry to enhance the nutritional characteristics and stability of oil at an affordable price. Microencapsulation of these oils provides a functional barrier of core and coating material from the adverse environmental conditions, thereby enhancing the oxidative stability, thermo-stability, shelf-life, and biological activity of oils. Microencapsulation of oils has been conducted and commercialized by employing different conventional methods including emulsification, spray-drying, freeze-drying, coacervation, and melt-extrusion compared with new, improved methods like microwave drying, spray chilling, and co-extrusion. The microencapsulated oil emulsion can be either dried to easy-to-handle solids/microcapsules, converted into soft solids, or enclosed in a gel-like matrix, increasing the shelf-life of the liquid oil. The omega-rich microcapsules have a wide application in confectionery, dairy, ice-cream, and pharmaceutical industries. This review summarizes recent developments in blending and microencapsulation technologies in improving the stability and nutritional value of edible oils.

A systematic review and meta-analysis of fish oil encapsulation within different micro/nanocarriers

Fish oil is one of the most important sources of omega 3 polyunsaturated fatty acids (PUFAs), especially eicosapentaenoic acid and docosahexaenoic acid which are the most important PUFAs with several health benefits. However, PUFAs are prone to oxidation and have a poor water solubility which limits the use of fish oils into food formulations. Encapsulation techniques can be applied to overcome these challenges. There is a large number of published micro/nanoencapsulation papers, where each of them contains a limited number of wall materials, feed formulation, encapsulation technique, and storage conditions. Therefore, without systematic evaluation of the data extracted from available studies, the design of functional foods containing fish oil would not be very successful. The objective of this systematic review is a meta-analysis of published researches on the nano/microencapsulation of fish oil. A comprehensive literature search was performed between 1 October and 31 December 2019 with encapsulation, fish oil, and oxidative stability keywords. Overall, 39 qualified articles were selected for the statistical analysis. Based on the technique used for encapsulation, the fish oil-loaded carriers were classified into four main groups: (a) spray-dried particles; (b) freeze-dried particles; (c) electrospun fibers and electrosprayed capsules; and (d) other carriers prepared by supercritical antisolvent, gelation, liposomes, spray-freeze drying, and transglutaminase catalyzed cross-linking. The three most frequent methods applied for fish oil encapsulation were spray drying (42.86%), freeze drying (21.43%), and electrohydrodynamic (19.04%) methods, respectively. Averagely, the best encapsulation efficiency was obtained for electrohydrodynamic processes. Also, the combination of polysaccharide-protein based wall materials provided the best performance in terms of fish oil encapsulation efficiency.