Microencapsulation of <i>Lactobacillus helveticus</i> L‐6 by Electrostatic Spray Drying: Efficient Preparation and Characterization Analysis

ABSTRACT Lactobacillus helveticus ( L. helveticus ) is a widely used probiotic valued for its applications in food fermentation. Dried bacterial inoculants, known for ease of transportation, stability, and flexible formulation, are increasingly favored. However, traditional spray drying, despite its continuous production mode, often results in significant loss of active components. In contrast, freeze‐drying (FD) techniques, while preserving higher microbial viability, are limited by high energy costs and lengthy processing times. To address these challenges, this study employed an innovative electrostatic spray drying (ESD) technology for the preparation of L. helveticus inoculants. By optimizing microencapsulation techniques, heating temperature, and protective agents, a high‐activity inoculant was developed using a novel spray‐drying approach. The optimized inoculant achieved an initial survival rate of 82%, a production yield of 69.36%, residual moisture of 3.50%, water activity (aw) of 0.08, cell membrane integrity of 93.50%, and energy consumption of 7.5 kWh/L. After 3 months of storage at 4°C, survival rate remained at 79% with aw increasing to 0.22—well below the microbial growth threshold (aw 0.60)—and retained a smooth, crack‐free microstructure. Fermentation performance analysis revealed that ESD‐prepared inoculants outperformed freeze‐dried inoculants. Although ESD extended the lag phase by 6 h compared to traditional liquid seed cultures, its fermentation efficiency remained comparable. This technology provides an efficient and standardized solution for large‐scale production of L. helveticus in food fermentation, offering a promising alternative to conventional methods.