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ORIGINAL ARTICLE Direct spray drying and microencapsulation of probiotic Lactobacillus reuteri from slurry fermentation with whey M. Jantzen, A. Gopel and C. Beermann Department of Biotechnology, University of Applied Sciences Fulda, Fulda, Germany Keywords bacterial release, bacterial survival, Lactobacillus reuteri, microencapsulation, probiotic, spray drying, whey. Correspondence Christopher Beermann, Faculty of Food Technology, Department of Biotechnology, University of Applied Sciences Fulda, Mar- quardstrasse 35, Fulda, 36039, Germany. E-mail: [email protected] 2013/0751: received 19 April 2013, revised 10 June 2013 and accepted 20 June 2013 doi:10.1111/jam.12293 Abstract Aims: Formulations of dietary probiotics have to be robust against process conditions and have to maintain a sufficient survival rate during gastric transit. To increase efficiency of the encapsulation process and the viability of applied bacteria, this study aimed at developing spray drying and encapsulation of Lactobacillus reuteri with whey directly from slurry fermentation. Methods and Results: Lactobacillus reuteri was cultivated in watery 20% (w/v) whey solution with or without 0 5% (w/v) yeast extract supplementation in a submerged slurry fermentation. Growth enhancement with supplement was observed. Whey slurry containing c. 10 9 CFU g 1 bacteria was directly spray- dried. Cell counts in achieved products decreased by 2 log cycles after drying and 1 log cycle during 4 weeks of storage. Encapsulated bacteria were distinctively released in intestinal milieu. Survival rate of encapsulated bacteria was 32% higher compared with nonencapsulated ones exposed to artificial digestive juice. Conclusions: Probiotic L. reuteri proliferate in slurry fermentation with yeast- supplemented whey and enable a direct spray drying in whey. The resulting microcapsules remain stable during storage and reveal adequate survival in simulated gastric juices and a distinct release in intestinal juices. Significance and Impact of the Study: Exploiting whey as a bacterial substrate and encapsulation matrix within a coupled fermentation and spray-drying process offers an efficient option for industrial production of vital probiotics. Introduction The Food and Agriculture Organization of the United Nations and the World Health Organization underline in their definition of probiotics that living micro-organisms with health-promoting mechanisms have to be adminis- tered in adequate amounts to be effective (FAO and WHO 2001). Therefore, dietary formulations of probiotics have to be robust against industrial production processes in a cost-effective way and should maintain a sufficient survival rate after oral uptake and gastrointestinal tract (GIT) transit. Commonly accepted bacterial counts for dietary prod- ucts are at least 10 6 CFU ml 1 (Kailaspathy and Chin 2000). A wide range of health benefits have been described, such as immune response-modulating proper- ties, improving gut barrier function and protecting effects of the colon against pathogens (Anal and Singh 2007). Lactobacillus reuteri strains are probiotic lactic acid bacte- ria (LAB) regularly applied to milk-related products but also in meat, fruit and vegetable-based products. Further- more, L. reuteri has been described to be a robust bacte- rium feasible for large-scale cultivation techniques and has high viability during storage and production (Casas and Dobrogosz 2000). Probiotic encapsulation is a multi-stage process which includes fermentation, harvesting, resuspension in matrix material and encapsulation. To increase process efficiency and improve the survival of bacteria, this study aimed at developing a microencapsulation process for L. reuteri by spray drying directly from slurry fermentation using whey as a culture substrate and encapsulation matrix. Several encapsulation procedures for bacteria have been estab- lished, predominantly emulsion, extrusion and spray Journal of Applied Microbiology 115, 1029--1036 © 2013 The Society for Applied Microbiology 1029 Journal of Applied Microbiology ISSN 1364-5072

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  • ORIGINAL ARTICLE

    Direct spray drying and microencapsulation of probioticLactobacillus reuteri from slurry fermentation with wheyM. Jantzen, A. Gopel and C. Beermann

    Department of Biotechnology, University of Applied Sciences Fulda, Fulda, Germany

    Keywords

    bacterial release, bacterial survival,

    Lactobacillus reuteri, microencapsulation,

    probiotic, spray drying, whey.

    Correspondence

    Christopher Beermann, Faculty of Food

    Technology, Department of Biotechnology,

    University of Applied Sciences Fulda, Mar-

    quardstrasse 35, Fulda, 36039, Germany.

    E-mail: [email protected]

    2013/0751: received 19 April 2013, revised

    10 June 2013 and accepted 20 June 2013

    doi:10.1111/jam.12293

    Abstract

    Aims: Formulations of dietary probiotics have to be robust against process

    conditions and have to maintain a sufficient survival rate during gastric transit.

    To increase efficiency of the encapsulation process and the viability of applied

    bacteria, this study aimed at developing spray drying and encapsulation of

    Lactobacillus reuteri with whey directly from slurry fermentation.

    Methods and Results: Lactobacillus reuteri was cultivated in watery 20% (w/v)

    whey solution with or without 05% (w/v) yeast extract supplementation in asubmerged slurry fermentation. Growth enhancement with supplement was

    observed. Whey slurry containing c. 109 CFU g1 bacteria was directly spray-dried. Cell counts in achieved products decreased by 2 log cycles after drying

    and 1 log cycle during 4 weeks of storage. Encapsulated bacteria were

    distinctively released in intestinal milieu. Survival rate of encapsulated bacteria

    was 32% higher compared with nonencapsulated ones exposed to artificial

    digestive juice.

    Conclusions: Probiotic L. reuteri proliferate in slurry fermentation with yeast-

    supplemented whey and enable a direct spray drying in whey. The resulting

    microcapsules remain stable during storage and reveal adequate survival in

    simulated gastric juices and a distinct release in intestinal juices.

    Significance and Impact of the Study: Exploiting whey as a bacterial substrate

    and encapsulation matrix within a coupled fermentation and spray-drying

    process offers an efficient option for industrial production of vital probiotics.

    Introduction

    The Food and Agriculture Organization of the United

    Nations and the World Health Organization underline in

    their definition of probiotics that living micro-organisms

    with health-promoting mechanisms have to be adminis-

    tered in adequate amounts to be effective (FAO and

    WHO 2001). Therefore, dietary formulations of probiotics

    have to be robust against industrial production processes

    in a cost-effective way and should maintain a sufficient

    survival rate after oral uptake and gastrointestinal tract

    (GIT) transit.

    Commonly accepted bacterial counts for dietary prod-

    ucts are at least 106 CFU ml1 (Kailaspathy and Chin2000). A wide range of health benefits have been

    described, such as immune response-modulating proper-

    ties, improving gut barrier function and protecting effects

    of the colon against pathogens (Anal and Singh 2007).

    Lactobacillus reuteri strains are probiotic lactic acid bacte-

    ria (LAB) regularly applied to milk-related products but

    also in meat, fruit and vegetable-based products. Further-

    more, L. reuteri has been described to be a robust bacte-

    rium feasible for large-scale cultivation techniques and

    has high viability during storage and production (Casas

    and Dobrogosz 2000).

    Probiotic encapsulation is a multi-stage process which

    includes fermentation, harvesting, resuspension in matrix

    material and encapsulation. To increase process efficiency

    and improve the survival of bacteria, this study aimed at

    developing a microencapsulation process for L. reuteri by

    spray drying directly from slurry fermentation using whey

    as a culture substrate and encapsulation matrix. Several

    encapsulation procedures for bacteria have been estab-

    lished, predominantly emulsion, extrusion and spray

    Journal of Applied Microbiology 115, 1029--1036 2013 The Society for Applied Microbiology 1029

    Journal of Applied Microbiology ISSN 1364-5072

  • drying (Anal and Singh 2007; Rokka and Rantamaki

    2010). Both extrusion and emulsion mainly generate wet

    particles by cross-linking polymer systems which have to

    be dried to enable handling and storage afterwards (Cook

    et al. 2012).

    Encapsulation by spray drying directly achieves optimal

    product moisture content, which is between 4 and 7% for

    storage stability (Ananta et al. 2005). Other main advanta-

    ges of spray drying are its low cost and fast production of

    large quantities of viable cells (De Castro-Cislaghi et al.

    2012). Hereby, predominant factors for bacterial viability

    loss in this process are heat, oxygen, as well as mechanical

    and osmotic forces (Meng et al. 2008). In contrast, encap-

    sulation with spray drying yields dried powder of small

    particle sizes with a sufficient protection for the core (Anal

    and Singh 2007; Cook et al. 2012).

    Several spray-drying processes for dietary applications

    have been established utilizing different polysaccharides

    and protein compounds to protect probiotics. The pH

    value profile of the gastrointestinal passage ranges from 19to 25 in the stomach, which is the most harmful for orallyapplied probiotics, up to pH values between 615 and 788in the small intestine and ending up with a slightly acidic

    pH value in the colon (Cook et al. 2012). Also, digestive

    enzymes, such as gastric pepsin and pancreatic trypsin and

    chymotrypsin, pancreatin and bile salts are further antibac-

    terial factors (Gbassi et al. 2011; Doherty et al. 2012).

    Whey is a cheap cheese by-product containing 50% of

    the milk nutrients, predominantly lactose (49% of totalwhey) and whey protein (07% of total whey) with themain protein fractions b-lactoglobulin and a-lactalbumin.With its dissimilar nutritional value, whey possesses

    different interesting bio- and techno-functional proper-

    ties. Aside from specific lipids, vitamins, minerals and

    high-energetic lactose, whey has been discussed to be an

    attractive source of functional proteins and peptides with

    distinct amino acid profiles (Smithers 2008). To con-

    tinue, whey is thermostable and possess excellent gelation,

    water binding, emulsification as well as foam forming

    properties and foam formation with thermal stability

    (Foegeding et al. 2002; Smithers 2008). Recent studies

    suggest that whey protein resists against acidic milieus

    (Doherty et al. 2012). Gbassi et al. (2009) determined no

    damaging effect at pH 18. The stability against pepsin ismore complex as a-lactalbumin breaks down in the pres-ence of pepsin, while the main whey protein b-lactoglob-ulin stays intact (Gbassi et al. 2009).

    Considering the physiological and technological poten-

    tial, whey might be useful as a bacterial substrate and

    encapsulation matrix within a coupled fermentation and

    spray-drying process to offer an efficient option for

    industrial production of vital probiotics. For this, the

    growth of L. reuteri in whey was characterized in batch

    slurry fermentation process coupled with direct encapsu-

    lation of bacteria by spray drying. At last, physical prod-

    uct characteristics and bacterial protective properties

    against GIT conditions were investigated in vitro.

    Materials and methods

    Bacterial strain

    Probiotic Lactobacillus reuteri (DSM 20016) was obtained

    from the German Collection of Microorganisms and Cell

    Cultures Leibnitz Institute DSMZ and cultured aero-bically in 9 ml de ManRogosaSharpe (MRS) broth (pH62) at 37C for 24 h.

    Growth of Lactobacillus reuteri in whey

    To characterize the growth of L. reuteri in whey,

    approximately 103 CFU ml1 bacteria were inoculated ina 200-ml-volume fermentation of watery 20% (w/v) whey

    solution (pH 60) with or without 05% (w/v) yeastextract as supplement and cultivated in a agitating flask

    culture at 37C. Before inoculation, whey solution wassterilized in 80C water bath for 20 min. Bacterial cellcount was measured after 0, 24, 48 and 72 h by direct

    plate counting as described below.

    Batch slurry fermentation of Lactobacillus reuteri in a

    continuous stirred-tank reactor (CSTR)

    The growth of L. reuteri was observed in a laboratory-scale

    reactor (Biostat A, Sartorius Ltd., Melsungen, Germany).

    Approximately 104 CFU ml1 bacteria were inoculated in1 l batch slurry fermentation of watery 20% (w/v) whey

    solution with 05% (w/v) yeast extract as supplement,tested with adjustment at pH 50 and cultivated at 37Cwith agitation using one six-wing rotating disc at 200 rpm,

    respectively. Samples of 5 ml were taken to determine cell

    counts after 0, 24, 48 and 72 h by direct plate counting as

    described below.

    Microencapsulation of Lactobacillus reuteri in whey

    For the spray-drying process, a 48-h-incubated 200-ml

    slurry culture of L. reuteri with at least 108 CFU ml1 wasapplied. The fermented slurry was spray-dried by a labora-

    tory-scale spray dryer (Buchi mini spray dryer B190; Flawil,

    Switzerland) with two different outlet temperatures main-

    tained at 55 2 and 65 2C and a flow rate of 500 Nlh1. Outlet temperatures were reached by adjusting differ-ent inlet temperatures (89 1 and 100 1C) and feedlevels from 2 to 4 ml min1. Spray-dried powder sampleswere collected from the cyclone and mixed gently.

    1030 Journal of Applied Microbiology 115, 1029--1036 2013 The Society for Applied Microbiology

    Encapsulation of Lactobacillus from fermentation with whey M. Jantzen et al.

  • Enumeration of surviving cells

    To validate the survival rate of bacteria during drying

    process, cell counts were observed before and after spray

    drying. To detect the viable number of bacteria, direct

    plate counting was used. Samples were serially diluted in

    Ringers solution (pH 70) and plated on MRS agar (pH62). After 48-h incubation at 37C under anaerobic con-ditions, the cell counts were expressed in CFU g1.Spray-dried samples were previously rehydrated in

    Ringers solution at a solid content of 20% (w/v), and

    the solution was used to determine cell survival. Cell

    counts were expressed as mean values of duplicate

    measurements.

    Moisture content and particle size of spray-dried

    powders

    The moisture content of spray-dried powders was deter-

    mined using the moisture analyser (MA 40, Sartorius

    AG, Gottingen, Germany) at 80C drying temperature.Data are expressed as mean value of double-tested 1-g

    product.

    Particle size was analysed using the Mastersizer 2000

    (Malvern Instruments Ltd., Malvern, Worcestershire,

    UK). Data are expressed as mean value of triple determi-

    nations.

    Survival of encapsulated Lactobacillus reuteri during

    storage

    The spray-dried product was stored in plastic tubes at

    4C. Survival of encapsulated L. reuteri during storagewas determined directly following the drying process and

    after 1 week and 4 weeks of storage, by performing direct

    plate counting as described above.

    Survival and release of encapsulated and

    nonencapsulated Lactobacillus reuteri in simulated

    gastrointestinal conditions

    To estimate the tolerance of encapsulated cells to simu-

    lated digestive conditions, an assay was adapted by using

    a modified version of the method according to Picot

    and Lacroix (2004). The cultures were exposed to simu-

    lated gastric juice (pH 19) and afterwards to simulatedsmall intestinal juice (pH 75) at 37C. Simulated gastricjuice preparation contained pepsin (0304 g l1) (por-cine gastric mucosa, P7012, Sigma-Aldrich, Taufkirchen,

    Germany) dissolved in sterile 01 mol l1 HCl/1 mol l1NaOH to adjust pH to 19. Simulated pancreatic juicepreparation contained pancreatin (195 g l1) (porcinepancreas, P1750, Sigma-Aldrich) dissolved in sterile

    sodium phosphate buffer (002 mol l1, pH 75)adjusted with 01 mol l1 HCl/1 mol l1 NaOH to pH75. A concentrated bile salt solution contained bileextract powder (150 g l1) (bile bovine, B3883, Sigma-Aldrich) in sterile distilled water.

    To examine the survival of encapsulated L. reuteri,

    50 g of the dried product containing 107 CFU g1bacteria was gently mixed with 30 ml of pepsin prepara-

    tion (026 g l1, 37C) in a 50-ml sterile plastic tube.The resulting dispersion was incubated at 37C in a250 rpm shaking thermo element (ThermoMixer and

    BlockThermostate, HLC BioTech, Bovenden, Germany).

    After 30 min, the reaction was stopped by raising the pH

    to 75. A sample of 15 ml was taken and kept on icebefore viable cell counts were determined. A volume of

    25 ml of concentrated sodium phosphate buffer(05 mol l1, pH 75) and 10 ml of the concentratedbile salt solution were added (333 g l1). After adjustingthe pH to 75 and filling the volume to 405 ml withsterile distilled water, 45 ml of the simulated pancreaticjuice (195 g l1) was added to make the final volume ofthe tube to 45 ml. At different time intervals (1, 2, 3,

    5 h), 15-ml aliquots were taken and placed on ice beforebacterial enumeration. Except gentle shaking, no disper-

    sion step was conducted to estimate the release proper-

    ties of the microcapsules at different time intervals.

    For comparison, nonencapsulated bacteria cultured in

    MRS broth (37C, 24 h) were washed and resuspendedin sterile 085% saline. Five millilitres of cell suspensioncontaining approximately 106 CFU ml1 bacteria wasadded to 300 ml of pepsin preparation (026 g l1,37C) in a 50-ml sterile plastic tube and maintained at37C in a shaking thermo element, as described above.The rest of the procedure was same as that described for

    the encapsulated cells.

    Enumeration of bacteria from samples taken during

    simulated digestion with encapsulated and nonencapsu-

    lated cells was carried out by direct plate counting as

    described above. The percentage surviving bacteria was

    calculated as percentage survival = N/N0 9 100, whereN0 represents the number of bacteria in the inoculum

    and N is the viable number of bacteria in the digestion

    juice.

    Statistical analysis

    Data were evaluated by GraphPad 5 Prism software

    (GraphPad Software, Inc., La Jolla, CA, USA). P-values

    were determined by one-sided nonparametric WilcoxonMannWhitney U-test for tolerance to simulated gastricjuice and by two-sided nonparametric WilcoxonMannWhitney U-test for storage, moisture content and particle

    size. P-values 005 were defined as significant.

    Journal of Applied Microbiology 115, 1029--1036 2013 The Society for Applied Microbiology 1031

    M. Jantzen et al. Encapsulation of Lactobacillus from fermentation with whey

  • Results

    Growth of Lactobacillus reuteri in whey

    The initial experiment was accomplished to define the

    growth capacity of L. reuteri (DSM 20016) in whey. For

    this, a watery 20% (w/v) whey solution with or without

    05% (w/v) yeast extract as supplement was tested. Underboth culture conditions, the stationary phase of bacterial

    growth kinetics of batch culture was reached after 48 h of

    fermentation in agitating flask at 37C. After 72-h cultur-ing, the end cell counts in pure whey solution increased 4

    log cycles, whereas the bacterial counts increased 5 log

    cycles by supplementing 05% yeast extract to whey.

    Batch slurry fermentation of Lactobacillus reuteri in a

    CSTR

    Yeast extractsupplemented whey solution was testedusing batch slurry fermentation in a CSTR. As sufficient

    agitation of whey slurry was reached at 200 rpm, station-

    ary growth phase was reached after 24 h of cultivation

    with 17 9 109 CFU g1 bacteria.

    Survival of Lactobacillus reuteri in whey encapsulation

    after spray drying

    Lactobacillus reuteri was spray-dried at 55 and 65C tem-peratures using the whole slurry fermentation with whey

    directly as feed. Loss of viable bacteria after spray drying

    is illustrated in Fig. 1. For all experiments, whey solutions

    with 16 ( 15) x 109 CFU g1 bacteria were applied tothe encapsulation process. Dried product contained 25( 17) x 107 CFU g1 bacteria directly after processingindependently from used outlet temperatures.

    Characterization of encapsulated particles

    To compare physical characteristics, moisture and particle

    size of the spray-dried products were determined

    (Table 1). The moisture content of dehydrated products

    is of importance for product and bacterial stability while

    storage. Optimal moisture content is between 4 and 7%

    for storage (Ananta et al. 2005). Powder manufactured in

    this study had a mean moisture content of about 65(07)%. There is no significant difference in moisturecontent of the powder produced at 55 or 65C outlettemperature of the process. The obtained particles had a

    mean diameter of 55 (03) lm at 55C and 49 (03)lm at 65C again with insignificant differences withregard to the outlet temperatures. Achieved size is big

    enough to encapsulate rod-shaped L. reuteri cells with

    about 2 lm length (Muthukumarasamy et al. 2006).

    To describe product stability during storage at 4C,survival of encapsulated bacteria was determined after

    1 week and 4 weeks. The bacterial counts of the pro-

    duced capsules decreased by 1 log cycle after a storage

    period for 4 weeks (Fig. 1).

    Survival and release of encapsulated and

    nonencapsulated Lactobacillus reuteri in simulated

    gastrointestinal conditions

    To ensure the physio-functional benefits of L. reuteri, a

    sufficient bacterial survival rate along the stomach and

    intestine passage is essential to enable probiotic coloniza-

    tion of the colon. Figure 2 examines the survival of free

    and encapsulated cells after exposure to artificial digestive

    juices, first 30 min in simulated gastric juice and after-

    wards in simulated intestinal juice for a maximum of 5 h

    in vitro.

    Inoculation in artificial gastric juice resulted in a

    decline in viable cell counts of L. reuteri. Observed cell

    counts after 30 min were 12% of the applied bacteria for

    free cells and about 26% for encapsulated ones. After

    changing to simulated intestinal juice, the number of via-

    ble cell counts for nonencapsulated bacteria remained

    constant. In contrast, cell counts for encapsulated ones

    Before After 7 days 28 days100

    102

    104

    106

    108

    1010

    Process Storage

    CFU

    g1

    Figure. 1 Cell counts of Lactobacillus reuteri before and after spray-

    drying process with ( ) 55C and ( ) 65C outlet temperatures

    and during storage for 7 and 28 days at 4C storage temperature.

    The data shown represent the mean of at least three measurements.

    Table 1 Moisture content and particle size of spray-dried powder

    directly from slurry fermentation in whey 20% (w/v) with 05% (w/v)yeast extract supplementation

    Process outlet temperature (C) Moisture (%) Particle size (lm)

    55 61 08 55 0365 68 03 49 03

    Results for 55 and 65C are the mean of triplicate trials.

    1032 Journal of Applied Microbiology 115, 1029--1036 2013 The Society for Applied Microbiology

    Encapsulation of Lactobacillus from fermentation with whey M. Jantzen et al.

  • increased during exposure to intestinal juice due to a

    distinct release of encapsulated bacteria reaching a sur-

    vival rate of 54% after 3 h. Thus, after 5 h in digestive

    juices, nonencapsulated L. reuteri revealed 86% loss of

    living cells, whereas processed bacteria revealed a loss of

    54% under simulated gastrointestinal conditions. There-

    fore, survival rate of L. reuteri increased approximately

    32% with encapsulation in whey matrix compared with

    nonprocessed ones.

    The statistical analysis testified the difference between

    the reduction in cell counts of free and encapsulated cells

    to be significant. Results show an improved survival rate

    of L. reuteri in encapsulated forms.

    Discussion

    Aside lactose, vitamins and several minerals, whey con-

    tains a complex protein composition predominated by

    b-lactoglobulin and a-lactalbumin. These proteins possessa distinct amino acid profile and are a significant nitro-

    gen source for bacteria, whereas whey lactose is a relevant

    carbohydrate source. In this study, the nutritive value of

    whey and the distinct characteristics of solubility, dena-

    turation, dissociation and aggregation dependent on pH

    value and temperature of these components were used to

    cultivate probiotic L. reuteri (DSM 20016) for a coupled

    encapsulation process within this matrix by spray drying

    instead of harvesting the bacteria out of the fermentation

    medium and resuspending in encapsulation material. In

    this study, L. reuteri reached cell counts of 22 9108 CFU g1 in pure whey. On the one hand, bacterialb-galactosidase activity is necessary to metabolize lactose,which is generally shown by L. reuteri (Hidalgo-Morales

    et al. 2011). Most LABs are able to digest whey due to

    the high proteolytic activity (Pescuma et al. 2012).

    However, L. reuteri possesses low proteolytic activity

    (Hidalgo-Morales et al. 2011), and therefore, supplemen-

    tation with extra nitrogen sources might improve growth.

    Parente and Zottola (1991) suggested supporting LAB

    cultivation in native whey with nutritive complex addi-

    tives such as yeast extract. Furthermore, an increased

    whey protein concentration to raise nitrogen source for

    the bacteria has been described to be helpful (Bury et al.

    1998). In this study, the bacterial growth could be

    improved to maximum cell counts of up to 27 9109 CFU g1 with yeast extract supplementation.For encapsulation, bacteria in stationary phase with

    reduced proliferation rate, less physiological activity and

    increased resistance to stress seem to be most appropri-

    ate for spray drying. Corcoran et al. (2004) revealed

    approximately 50% higher survival rates of L. reuteri

    within spray-drying processes if bacteria were taken

    from stationary-phase cultures. Further, for spray-drying

    processes, matrices with 20% solid content are recom-

    mended (Desmond et al. 2001; Ananta et al. 2005). In

    consequence, to couple cultivation and spray-drying pro-

    cess, bacterial growth up to stationary phase should be

    possible in 20% whey slurry fermentation. In this study,

    L. reuteri reached the stationary phase at least after 24 h

    in a slurry fermentation in CSTR.

    Generally, spray drying is an effective way to produce

    probiotic encapsulation with high survival rates and

    improved resistance during gastric transit (Malmo et al.

    2011; Paez et al. 2012). One critical factor for bacterial

    survival within the drying process is the exposure to hot

    air which leads to heat and osmotic stress for the cells.

    Otherwise, high temperatures are required to facilitate

    sufficient water evaporation along the process as dried

    product contains at best moisture of 4 and 7% for good

    stability of dried implementations throughout storage

    (Ananta et al. 2005). Hereby, heat sensitivity of the bacte-

    rial strain and hygroscopic properties of the encapsula-

    tion material are important factors (Ananta et al. 2005;

    Golowczyc et al. 2011). Survival of heat-sensitive L. para-

    casei during spray drying ranged from 97% (outlet

    temperature 7075C) to 0% (outlet temperature 120C)(Gardiner et al. 2000). Other Lactobacilli strains spray-

    dried in skim milk at 85C outlet temperature reachedhigher survival rates (loss of 016095) (Paez et al.2012). Malmo et al. (2011) revealed a loss of 1631 logof L. reuteri (DSM 17938) after spray drying with alginate

    matrix at 72C outlet temperature. Higher survival ratesof spray-dried L. reuteri (KUB-AC5) were measured at

    70C outlet temperature with a variation of 8393% sur-vival depending on the growth media (Hamsupo et al.

    2005). Taking the distinct heat sensitivity of bacteria into

    consideration, the viability can be enhanced by lowering

    the outlet temperature (Lian et al. 2002; Meng et al.

    0 1 2 3 4 50

    20

    40

    60

    80

    100

    05 h

    Surv

    ival a

    nd re

    leas

    e %

    Gastric juice intestinal juice

    Figure. 2 Percentage release and survival of () encapsulated and ()nonencapsulated Lactobacillus reuteri in simulated gastric juice for

    30 min and afterwards in simulated intestinal juice for a maximum of

    5 h. The data shown represent the mean of at least three measure-

    ments.

    Journal of Applied Microbiology 115, 1029--1036 2013 The Society for Applied Microbiology 1033

    M. Jantzen et al. Encapsulation of Lactobacillus from fermentation with whey

  • 2008). In this study, both outlet temperatures 55 and

    65C lead to sufficient dry powder with a negligible viablecell decrease of 2 log cycles (213% mean survival rate)after spray drying due to dehydration and thermal

    damages of bacterial cell structures (Fig. 1).

    Although small-sized particles are less affecting textural

    and sensorial food qualities, the particle size must at least

    enable total bacterial encapsulation (Chen and Subirade

    2006). In this study, the process produced small particles

    sized 5 lm in mean (Table 1), which are large enough toencapsulate L. reuteri cells (Anal and Singh 2007). Gener-

    ally, decreasing moisture content correlates with an

    increasing temperature in the drying process (Lian et al.

    2002; Anandharamakrishnan et al. 2008). In this study,

    however, neither particle size nor moisture content of

    capsule parameters were significantly affected by chosen

    outlet temperatures of the drying process. Desmond et al.

    (2001) described the possibility that milk proteins are

    useful to protect probiotic cultures during heating. Fur-

    thermore, lactose from whey protein might synergistically

    improve the micro-organism-protecting properties of

    these proteins. Young et al. (1993) discovered synergistic

    effect of whey proteins and carbohydrates for microen-

    capsulation by spray drying. They described higher

    microencapsulation efficiency using the combination of

    whey protein and carbohydrates. Additionally, an

    increased thermotolerance of LAB resulting in high

    survival rates during storage was observed if growth

    media contained lactose (Carvalho et al. 2004). The pro-

    tection of dehydrated biomaterials by sugars is mainly

    due to hydrogen bonds with the proteins when water is

    removed (Rokka and Rantamaki 2010). And lactose has

    been discussed to stabilize the bacterial cell wall by induc-

    ing a crusty glass phase (Rosenberg and Sheu 1996). Also,

    Rokka and Rantamaki (2010) underlined that skim milk

    and lactose, often in combination with milk proteins, are

    widely used as protective agents within spray-drying

    processes.

    As dietary products contain at least 106 CFU ml1 bac-teria, the survival of probiotics during storage is impor-

    tant to assess product applicability (Kailaspathy and Chin

    2000). Different studies have illustrated that the bacterial

    survival rate was most sufficient at 4C storage tempera-ture (Corcoran et al. 2004; Silva et al. 2011). In this

    study, the examined loss in viable cells was at maximum

    1 log cycle after a storage period of 4 weeks at 4C(Fig. 1). Depending on the outlet temperature, the viable

    counts during storage decreased at 65C by about 1 logcycle and at 55C by

  • probably due to whey protein degradation by pancreatin

    (Fig. 2). Accordingly, Chen and Subirade (2006)

    described a release of whey protein capsule core material

    into simulated intestinal juice with pancreatin.

    In conclusion, whey exploited as growth substrate and

    encapsulation matrix within a coupled fermentation and

    spray-drying process might offer an efficient option for

    industrial production of vital probiotics. The resulting

    microcapsules remain stable during storage and reveal ade-

    quate survival in simulated gastric juices and a distinct

    release in intestinal juices. While lactose is supportive but

    also problematic in this coupled process, like unwanted

    caramelization or stickiness to the dryer wall, the influence

    of the whey-protein-to-lactose ratio on the process and

    product characteristics remains to be investigated.

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