The development of carotenoid-enriched functional foods is limited by the low stability of these bioactive compounds. The main objective of this study was to improve the stability of β-carotene through its encapsulation within emulsion-electrosprayed particles. Further, the particles with higher encapsulation efficiency was incorporated in meal replacement bar and investigated for their impact on bar quality and β-carotene content after bar baking. Ultrasonic power had a significant effect on the properties of emulsion, which are important to the properties of the particles. Moreover, the morphology of solidification product is related to the applied voltage connected to the spinneret and collector. The highest encapsulation efficiency, up to 39 ± 4%, was exhibited in the electrosprayed particles obtained from the emulsions prepared using a power of 360 W. β-Carotene and encapsulates incorporated bar retained their sensory characteristics and almost similar to control. Moreover, the encapsulation structures increased the stability of β-carotene after incorporated meal replacement bar.