Abstract
The increasing demand for functional foods is associated with the need to deliver probiotics through novel food matrices. In this study, a high-fiber high-protein composite flour matrix was selected as the food vehicle. To improve their stability, four encapsulation techniques (spray drying, freeze drying, spray-freeze drying, and refractance window drying) were used for the production of probiotic encapsulates in fructooligosaccharide: whey protein: maltodextrin matrix. Considering the need to develop customized/personalized products, the material supply was 3D printed using an in-house developed extrusion-based food 3D printer CARK (controlled additive-manufacturing robotic kit). The effect of four post-processing methods (freeze drying, refractance window drying, hot air drying, and microwave drying) was explored and the overall effect on probiotic stability during storage under two different conditions (4 °C and room temperature) was evaluated. No significant loss of probiotic viability was observed during the 3D printing process. Freeze drying method of post-processing achieved >90% survival rate for freeze dried and spray-freeze dried synbiotics incorporated products. Among the various treatments, spray-freeze-dried synbiotics incorporation followed by freeze drying post-processed 3D printed construct showed the best survival rate (79%) and viability (6.43 ± 0.17 log10 CFU/ml) under static in vitro digestion conditions. With around 96–98% survival rate with retained viability of 7.98 ± 0.48 log10 CFU/ml during the storage period of 35 days, the approach shows promising prospects for the delivery of probiotics in prebiotic matrices of customized shapes.
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