AbstractThe present study aims to optimize and explore the bee pollen as a functional component in milk powder using response surface methodology. The experimental design comprised of process variables: bee pollen (5–15%), temperature (20–30°C), and pressure (15–25 inHg) to investigate their effect on physical properties and total phenolic content of developed product. Results indicated an increase in powder recovery (41.53–52.96%) with pollen, temperature, and pressure whereas total phenolic content (12.35–22.65%) raised with pollen and pressure. The solubility (74.86–83.73%) and bulk density (0.37–0.63 g cm−3) decreased with pollen and temperature while hygroscopicity (13.10–18.29%) increased with pollen. The optimum conditions for polyphenol‐rich milk powder were 13.72% pollen, 26.84°C temperature, and 23.37 inHg pressure. Further, the morphological and FTIR analysis also strengthens the presence of polyphenols in optimized product. This investigation, thus, would open door for utilization of polyphenol‐rich milk powder in formulating several value‐added food products.Practical applicationsBee pollen—a potent source of essential amino acids, fatty acids, dietary fiber, and polyphenols is an underutilized but nourishing food. This study aims at developing the vacuum‐dried bee pollen—rich milk powder based on process variable: bee pollen concentration, temperature, and pressure. Results showed the significant amount of total phenolic compounds in developed milk powder that is even higher compared to fresh bee pollen. The powder manufacturing process discussed here is quite simple and can be easily adapted by small and medium scale industries to achieve drying at a lower cost which may be beneficial for beekeepers to raise their economic status in developing countries. Further, the developed polyphenol‐rich milk powder can be employed in cereals, bakery, confectionery, and frozen dessert industry to make healthier processed food products.