Search Results (387)

This study aimed to develop a functional powder using whey and milk matrices, leveraging the protective capacity of chia–alginate hydrogels and the advantages of electrohydrodynamic spraying (EHDA), a non-thermal technique suitable for encapsulating probiotic cells under stress conditions commonly encountered in food processing. A hydrogel matrix composed of chia seed mucilage and sodium alginate was used to form a biopolymeric network that protected probiotic cells during processing. The encapsulation efficiency reached 99.0 ± 0.01%, and bacterial viability remained above 9.9 log₁₀ CFU/mL after lyophilization, demonstrating the excellent protective capacity of the hydrogel matrix. Microstructural analysis using confocal laser scanning microscopy (CLSM) revealed well-retained cell morphology and homogeneous distribution within the hydrogel matrix while, in contrast, scanning electron microscopy (SEM) showed spherical, porous microcapsules with distinct surface characteristics influenced by the encapsulation method. Encapsulates were incorporated into beverages flavored with red fruits and pear and subsequently freeze-dried. The resulting powders were analyzed for moisture, protein, lipids, carbohydrates, fiber, and color determinations. The results were statistically analyzed using ANOVA and response surface methodology, highlighting the impact of ingredient ratios on nutritional composition. Raman spectroscopy identified molecular features associated with casein, lactose, pectins, anthocyanins, and other functional compounds, confirming the contribution of both matrix and encapsulants maintaining the structural characteristics of the product. The presence of antioxidant bands supported the functional potential of the powder formulations. Chia–alginate hydrogels effectively encapsulated L. reuteri, maintaining cell viability and enabling their incorporation into freeze-dried beverage powders. This approach offers a promising strategy for the development of next-generation functional food gels with enhanced probiotic stability, nutritional properties, and potential application in health-promoting dairy systems. Full article

This study aimed to microencapsulate Boesenbergia rotunda (fingerroot) extract using maltodextrin (MD) and gum arabic (GA) as wall materials via spray-drying to improve powder physicochemical properties and protect bioactive compounds. MD and GA were employed as wall materials in varying ratios (MD:GA of 1:0, 0:1, 1:1, 2:1, 1:2) to evaluate their effects on the physicochemical properties of the resulting microcapsules. Spray-dried microcapsules were evaluated for morphology, flowability, particle size distribution, moisture content, hygroscopicity, solubility, encapsulation efficiency, major bioactive compound retention, and thermal stability. The extract encapsulation using MD:GA at 1:1 ratio (MD1GA1) demonstrated a favorable balance, with high solubility (98.70%), low moisture content (8.69%), low hygroscopicity (5.08%), and uniform particle morphology, despite its moderate EE (75.06%). SEM images revealed spherical particles with fewer surface indentations in MD-rich formulations. Microencapsulation effectively retained pinostrobin and pinocembrin in all formulations with pinostrobin consistently retained at a higher value, indicating its higher stability. The balanced profile of physical and functional properties of fingerroot extract with MD1GA1 microcapsule makes it a promising candidate for food and nutraceutical applications. Full article

Background/Objectives: The integration of machine learning (ML) and artificial intelligence (AI) has revolutionized the pharmaceutical industry by improving drug discovery, development and manufacturing processes. Based on literature data, an ML model was developed by our group to predict the formation of binary co-amorphous systems (COAMSs) for inhalation therapy. The model’s ability to develop a dry powder formulation with the necessary properties for a predicted co-amorphous combination was evaluated. Methods: An extended experimental validation of the ML model by co-milling and X-ray diffraction analysis for 18 API-API (active pharmaceutical ingredient) combinations is presented. Additionally, one COAMS of rifampicin (RIF) and ethambutol (ETH), two first-line tuberculosis (TB) drugs are developed further for inhalation therapy. Results: The ML model has shown an accuracy of 79% in predicting suitable combinations for 35 APIs used in inhalation therapy; experimental accuracy was demonstrated to be 72%. The study confirmed the successful development of stable COAMSs of RIF-ETH either via spray-drying or co-milling. In particular, the milled COAMSs showed better aerosolization properties (higher ED and FPF with lower standard deviation). Further, RIF-ETH COAMSs show much more reproducible results in terms of drug quantity dissolved over time. Conclusions: ML has been shown to be a suitable tool to predict COAMSs that can be developed for TB treatment by inhalation to save time and cost during the experimental screening phase. Full article

Quercetin (Que) is widely recognized for its antioxidant and neuroprotective properties; however, its clinical potential remains limited due to poor solubility and low oral bioavailability. Nasal powders have emerged as a promising strategy to overcome these limitations, taking advantage of nose-to-brain delivery, offering a direct, non-invasive route to the central nervous system while bypassing first-pass metabolism. This study aims to extend previous work by systematically investigating the impact of different preparation methods (spray drying vs. lyophilization) and the incorporation of hydroxypropyl methylcellulose (HPMC) and mannitol/lecithin microparticles (MLMPs) on the physicochemical characteristics, structural properties, and in vitro diffusion behavior of HPβCD-based nasal powder formulations of Que. Thermal behavior and stability were analyzed using TGA, while morphology and particle distribution were assessed via Scanning Electron Microscopy. In vitro diffusion studies using Franz cells and regenerated cellulose membranes were conducted under simulated nasal conditions. Among all tested formulations, the spray-dried HPβCD/Que powder (F4) showed the highest permeation (0.11 ± 0.01 mg/cm² at 120 min). The inclusion of HPMC improved thermal stability but reduced Que diffusion, likely due to increased viscosity and matrix formation. Blending with MLMPs enhanced powder flow and dose placement, although it modestly reduced diffusion efficiency. Overall, this study highlights the potential of HPβCD-based spray-dried powders for nasal Que delivery and demonstrates how HPMC and MLMPs can be strategically employed to tailor performance characteristics. Full article

Interest in probiotics has not diminished, and techniques to protect them from the environment in which they are found are constantly being innovated. Spray-drying is the most studied and industrially used technique to encapsulate probiotics. Recently, a new process has been developed in which particle formation, alginate cross-linking, and drying are carried out in a single step. In this study, Bifidobacterium infantis, Bifidobacterium longum, Lactobacillus plantarum, and Lactobacillus rhamnosus were microencapsulated by spray-drying using a cross-linked alginate matrix supplemented with chia seed mucilage (CM) or flaxseed mucilage (FM) as the coating material. All formulations evaluated, supplemented with 0.4% (w/v) of CM or FM, including the control formulation showed high survival rates, varying between 87% and 97%. The viability of microencapsulated probiotics was affected by storage temperature. At 4 °C, viability decreased slightly, and after 90 days, the viable probiotic count ranged from 7 to 11 Log CFU/g of dry powder. Meanwhile, viability did not exceed 4 Log CFU/g of dry powder at 37 °C. Probiotic microencapsulation in cross-linked alginate matrices and chia or flaxseed mucilage by spray-drying is presented as a promising alternative for their protection, potentially improving the long-term stability and efficacy of the probiotic product. Full article

Background/Objectives: In this study, we present a green, scalable platform for the production of water-dispersible powders co-encapsulating the lipophilic bioactives curcumin (Cur) and eugenol (Eug) within the amphiphilic polymer Soluplus^® (SP) via low-temperature spray drying. Methods: The amount of Cur (1%, 5%, and 10%) and Eug (5%, 10%, 15%, and 20%) was varied to achieve single- and double-loaded water-soluble powders with the maximum amount of active substances. The powders containing a higher loading of Cur, 5% and 10% (and Eug), were obtained from water/ethanol mixtures (2:1 and 5:1 v/v ratio), while the formulation with 1% of Cur was spray-dried by using water as a solvent. Results: By leveraging aqueous or aqueous–ethanolic feed systems, we achieved high loading of the bioactive substances—up to 10% Cur and 20% Eug (w/w)—while minimizing organic solvent use. Myo-inositol was incorporated as a stabilizing excipient to modulate particle morphology, improve powder flowability, and enhance redispersibility. Physicochemical characterization revealed nanoscale micellization (53–127 nm), amorphization of both actives as confirmed by XRD and DSC, and the absence of crystalline residue. Encapsulation efficiencies exceeded 95% for Cur and 93% for Eug. Dissolution tests demonstrated a rapid release from the 5% Cur/5% Eug formulation (>85% in 5 min), while higher-loaded single-formulations showed progressively slower release (up to 45 min). Conclusions: This work demonstrates a robust and environmentally responsible encapsulation strategy, suitable for delivering poorly water-soluble phytochemicals with potential applications in oral nutraceuticals and pharmaceutical dosage forms. Full article

Spent osmotic solutions (sucrose, buckwheat honey, acacia honey, apple juice concentrate, chokeberry juice concentrate, cherry juice concentrate, and mannitol) were tested for their valorization to produce powders by spray drying. Simultaneously, the application of inulin as an alternative carrier was verified. The drying yield varied from 6 to 92%. For acacia honey, apple juice concentrate, chokeberry juice concentrate, and cherry juice concentrate, high stickiness was observed, which resulted in low yield and the production of significantly bigger particles of regular size distribution, higher hygroscopicity and bulk density, and better flowability. Sucrose, acacia honey, and mannitol were dried with lower stickiness, and the physical properties of the powders were acceptable. However, the yield of mannitol drying was low due to very small particles, low bulk density, and low cyclone efficiency. Therefore, sucrose and buckwheat honey solutions can be successfully spray dried using inulin as a carrier to produce powders suitable for further food applications. However, for the other tested materials, alternative carriers should be considered to reduce stickiness during drying. Full article

Green soybeans, or edamame (Glycine max L. Merril), serve as a superior source of phytochemicals and other nutritive substances and are commonly used as ingredients and additives in food products due to their polyphenols’ functional properties and antioxidant activity. Hence, it is very important to use a process to extract compounds with functional roles from plants as efficiently as possible. In this study, we sought to identify the optimal conditions for extracting genistein, belonging to the aglycone subgroup of isoflavones, from edamame using the cold plasma (CP) and enzyme method. Additionally, the impact of various drying techniques (spray-drying and freeze-drying) and storage conditions on the crude genistein extract powder was evaluated. The findings showed that the maximum values for the total phenolic content (TPC), total flavonoid content (TFC), and genistein (22.5 ± 0.23 mg of gallic acid equivalents (GAE)/100 g; 15.3 ± 0.13 mg of catechin equivalents (CAE)/100 g; and 12.6 ± 0.10 mg/100 g, respectively) were achieved under optimal pretreatment conditions using a CP gas flow rate of 5 L/min for 30 min, followed by enzymatic treatment at a specific enzyme concentration of 2.0% (v/v) for 240 min of incubation. Moreover, a scanning electron microscopy (SEM) analysis demonstrated that the CP and enzyme treatment induced significant structural changes, as evidenced by the presence of deeper pores on the surface of the powder granules. Spray-drying demonstrated a superior efficacy compared to freeze-drying for encapsulating the crude isoflavone extract. This study’s results also demonstrated that storage at 4 °C significantly stabilized the TPC, TFC, and genistein content and the antioxidant activity while preserving the physical properties (solubility and color) of the crude extract powder for up to 45 days. In summary, cold plasma pretreatment and enzymatic treatments offer practical solutions by enhancing the efficiency of non-thermal extraction processes, thereby increasing the yield of bioactive compounds, maintaining quality, and diminishing reliance on traditional, harsh methods. The elevated genistein content in the crude extract powder indicates its prospective application as a functional ingredient in various food and nutraceutical contexts. Full article

The effects of different carrier agents—pea protein (PP), rice protein (RP), bean protein (BP), whey protein (WP), and maltodextrin (MT, as a control)—on pitaya juice encapsulation via spray drying were evaluated. Juice and carrier mixtures (30% w/v) were dried at 150 °C, and the resulting powders were analyzed for water activity (aw), hygroscopicity (Hg), water solubility (WSI), bulk density (BD), glass transition temperature (Tg), water absorption (WAI), antioxidant activity (AA), total polyphenol content (TPC), total betalain (TB) content, and TB stability. Vegetable proteins showed promising results, significantly impacting the protein content, Hg content, WAI, WSI, AA, TPC, and TB content and resulting in high Tg values. PP showed the best results, with high betalain retention (>30%), high TPC and AA, high protein levels, and low Hg, similarly to MT. WP had the highest TB, AA, and TPC but the lowest Tg (47.21 °C), thus reducing stability. Encapsulates obtained with plant protein-based wall materials presented high Tg (>58 °C); low aw, WSI, and Hg; high protein contents >40%; and adequate retention of bioactive compounds, with low degradation rate constants and long half-lives. Overall, plant proteins are promising alternatives to traditional carriers, offering improved stability and functionality in encapsulated products. Full article

Background/Objectives: Controlling the critical quality attributes (CQAs), such as granule moisture level and particle size distribution, that impact product performance is essential for ensuring product quality in medicine manufacture. Oral solid dosage forms, such as tablets, often require appropriate powder flow for compaction and filling. Spray-dried fluidized bed granulation (FBG) is a key unit operation in the preparation of granulated powders. The determination of particle sizes in FBG using near-infrared spectroscopy (NIR) has been considered in the literature. Herein, for the first time, NIR is combined with process parameters to achieve improved prediction of the particle sizes in FBG. Methods: An inline model for particle size determination using both NIR and FBG process parameters was developed using the partial least square (PLS) method, or ‘merged-PLS model’. The particle size was predicted at the end point of the process, i.e., the last 10% of the particle-size data for each batch run. An additional two analyses included a merged-PLS model with 12 batches: (1) where nine batches were training and three batches were a test set; and (2) where 11 batches were training and one was a test batch. Results: For all considered particle size fractions, Dv10, Dv25, Dv50, Dv75, and Dv90, an improved root-mean-squared error of prediction (RMSEP) is obtained for the merged-PLS model compared to the NIR-only PLS model and compared to the process parameters alone model. Improved RMSEP is also achieved for the additional two analyses. Conclusions: The improved prediction performance of endpoint particle sizes by the merged-PLS model can help to enhance both the process understanding and the overall control of the FBG process. Full article

Background/Objectives: In vitro, vancomycin (VAN) and tetrahydrolipstatin (THL) together have been shown to synergistically inhibit Mycobacterium tuberculosis (Mtb), the world’s most infectious killer. The poor oral bioavailability of VAN and THL and predominant tropism of Mtb infection to the lungs and alveolar macrophages make pulmonary administration highly attractive. This study aimed to develop and assess the efficacy of dry powders for inhalation of VAN microparticles embedded with THL. Methods: The dry powders produced by spray-drying, with or without hydrogenated castor oil (HCO), were characterized for their physicochemical properties among others by HPLC-DAD. The fast-screening impactor was used to determine powder aerodynamic properties, and VAN and THL releases were established from the paddle over disk method. Biological activities were assessed in a new M. bovis-infected macrophage model and in Mtb-infected mice. Results and Discussion: The addition of 25% HCO enables co-deposition (fine particle dose) at the desired weight ratio and co-releasing of VAN and THL in aqueous media. Microparticles with 0% to 50% HCO drastically reduced cytoplasmic Mycobacterium bovis survival (99.9% to 62.5%, respectively), with higher efficacy at low HCO concentration. Consequently, VAN/THL with or without 25% HCO was evaluated in Mtb-infected mice. Although no decrease in Mtb lung burden was observed after two weeks of administration, the endotracheal administration of VAN 500 mg/kg and THL 50 mg/kg with 25% HCO administrated three times during five days concomitantly with daily oral rifampicin (10 mg/kg) demonstrated 2-fold bacterial burden reduction compared to the group treated with RIF alone. Conclusions: HCO was crucial for obtaining a fine particle dose at the synergistic weight ratio (VAN/THL 10:1) and for releasing both drugs in aqueous media. With oral administration of the first-line rifampicin, the dry powder VAN/THL/25% HCO was able to exert a potential anti-tubercular effect in vivo in Mtb-infected mice after five days. Full article

Background/Objectives: Spray drying is a technique widely employed in the food and nutraceutical industries to convert liquid extracts into stable powders, preserving their functional properties. Ginger (Zingiber officinale) is rich in bioactive compounds such as gingerols, shogaols, and zingerone, which contribute to its health benefits. This study aimed to investigate the impact of spray drying on the chemical profile of ginger, particularly focusing on the transformation of gingerols into shogaols and related compounds. Methods: Fresh ginger juice was spray-dried using various carrier agents, including Clear Gum (CO03), pea protein, and inulin. Mass spectra of the resulting powders were acquired using High-Resolution Flow Infusion Electrospray Ionisation Mass Spectrometry (HR-FIE-MS) to obtain fingerprint data. Key bioactive compounds were tentatively identified to Level 2, and their relative intensities were assessed to evaluate the effects of different carriers on the chemical composition of the ginger powders. Results: Spray drying with the commercial carrier CO03 resulted in an increase in shogaol analogues ([10]-, [8]-, and cis-[8]-shogaol), gingerenone B, and oxidation products such as 6-hydroxyshogaol, 6-dehydroshogaol, and zingerone. In contrast, natural carriers like pea protein and inulin led to lower relative intensities of these bioactives, suggesting limited capacity for promoting thermal transformations. Spray drying without a carrier produced a shogaol-dominant profile but resulted in powders with poor handling properties, such as stickiness and agglomeration. Antioxidant and total polyphenol assays showed that spray drying reduced antioxidant capacity, while total polyphenol content was more preserved; natural carriers such as inulin better maintained bioactivity compared to modified starch or pea protein. Conclusions: Among the five formulations evaluated—ginger juice with no carrier, with CO03 (two dilutions), pea protein, or inulin—CO03-based samples showed the greatest chemical transformation, while inulin and pea protein better preserved antioxidant capacity but induced fewer metabolite changes. Thus, choice of carrier in the spray-drying process influences the chemical profile and functional characteristics of resultant ginger powders. While CO03 effectively enhances the formation of bioactive shogaols and related compounds, its ultra-processed nature may not align with clean-label product trends. Natural carriers, although more label-friendly, may not create the desired chemical transformations. Therefore, optimising carrier selection is important to balance bioactivity, product stability, and consumer acceptability in the development of ginger-based functional products. Full article

Spray-drying is a flexible method for creating fine porous composites with controlled size and morphology. This study investigates how the morphology and porosity of the spray-dried powder of nano-alumina and polyvinylpyrrolidone (PVP-30) granules are affected by both the feed rate and the binder concentration. Droplet size and velocity distributions, measured with a HiWatch system, showed that higher feed rates produce larger droplets with faster velocities, therefore affecting the final morphology of the dried product. The morphology of the dried granules was analyzed using inline SOPAT imaging. While mercury intrusion porosimetry quantified the nano-pore volume and nano-pore size of the granules, offline scanning electron microscopy (SEM) was also used to characterize the morphology of the dried product. The findings show that, while raising the binder concentration produces a more compact morphology with a lower nano-pore volume, higher feed rates produce larger granules with a larger nano-pore volume. This study offers fundamental insights that can support the future development of control strategies for optimizing the production of spray-dried porous alumina–polymer nanocomposites by means of knowledge about the relationship between these process parameters and product qualities. Full article

Young barley leaves have been proven to distinguish themselves as highly potent in antioxidant activity, resulting from a high content of bioactive compounds. Due to their short storage time, it is crucial to prolong their shelf life. One of the methods that can be used is spray-drying, as it enables the production of powders that are highly valued in the food industry. This paper aimed to analyze the possibility of producing young barley leaf juice with improved properties. Juices were spray-dried with and without carriers at 100/60 °C inlet/outlet temperature using air of 1.5 g/m³ humidity as the drying medium. Maltodextrin (MD), Nutriose^® (N), and Arabic gum (AG) were used in a ratio 1:3 carrier/juice solids. The results proved that dehumidified air application enabled the production of young barley leaf juice powder, that was free of the carriers, of high retention coefficient (RC) of chlorophyll A and B (80.84 ± 6.56% and 87.05 ± 5.21%, respectively). No statistical difference was noted between variants with maltodextrin (chlorophyll A: 91.22 ± 5.07%, chlorophyll B: 71.72 ± 5.44%), Nutriose^® (chlorophyll A: 72.24 ± 5.32%, chlorophyll B: 67.04 ± 12.41%), and carrier-free powder; thus, the elimination of a carrier can be considered to effectively produce a “clean” label, functional product. The highest degradation among the tested bioactive compounds was noted for vitamin C. Full article

The present investigation aimed to formulate and optimize sustained release proliposome dry powder for inhalation of Voriconazole (VZ) and its in vitro and in vivo evaluation. The proliposome-based dry powder for inhalation was formulated by spray drying technique using Phospholipon 90H and cholesterol in the lipid phase, mannitol as a carrier, and L-leucine as a dispersing agent. A face-centered central composite design was used to study the influence of factors on responses, vesicle size, VZ entrapment efficiency, and drug release. The optimized formulation was further characterized by FTIR, FESEM, DSC, XRD, and evaluated for in vitro drug release, in vitro aerosol deposition, and in vivo lung retention study in Wistar rats. For the optimized batch F-5 proliposome formulation, vesicle size was observed as 191.7 ± 0.049 nm with PDI 0.328 ± 0.009, entrapment efficiency as 72.94 ± 0.56%, and cumulative drug release after 8 h of dissolution was 82.0 ± 0.14%. The median mass aerodynamic diameter (MMAD) generated by optimized formulation F5 was significantly lower (3.85 ± 0.15 µm, p < 0.0001) as compared to spray-dried voriconazole (SD-VZ) (8.35 ± 0.23 µm). In vivo studies demonstrated a profound enhancement in lung retention (3.8-fold) compared to SD-VZ and oral VZ dispersion. Conclusively, proliposome formulation of voriconazole is a plausible and convincing approach for pulmonary fungal infections, considering its sustained release behaviour and prolonged lung retention. Full article