Tailoring wall material composition to improve volatile compound retention in spray-dried microparticles of smoke flavoring

Liquid smoke is widely used as a flavoring agent; however, its liquid form presents limitations related to handling, stability, and incorporation into dry food systems. Spray drying is a promising strategy for producing powdered smoke flavorings while preserving aroma compounds. Nevertheless, studies investigating how encapsulating matrix composition influences volatile retention and barrier properties remain limited. Therefore, this research hypothesized that combining maltodextrin with whey protein could improve volatile retention through film-forming properties. Feed solutions with liquid smoke:encapsulating agents (X 1 ) and whey protein isolate:maltodextrin (X 2 ) solid ratios ranging, respectively, from 5:95 to 15:85 and 0:100 to 30:70 were spray-dried and evaluated by response surface methodology. Volatiles were tentatively identified by gas chromatography–mass spectrometry. Furfural, creosol, 4-ethylguaiacol, and cerulignol peak areas were monitored by gas chromatography with flame ionization detection. Recovery was defined as the absolute fraction recovered in the collected powder, whereas retention represented its relative preservation independent of process yield. Only furfural recovery and furfural retention were statistically significant. Optimal conditions were obtained at a solid ratio of 10:90 (X 1 ) and 15:85 (X 2 ), averaging 50.8% drying yield, 23.5% furfural recovery, and 48.1% furfural retention. X-ray photoelectron spectroscopy indicated surface protein enrichment, while confocal microscopy showed co-localization of both materials within the particle wall. These observations suggest that whey protein altered particle wall organization and may have contributed to furfural retention during spray drying. This work opens new perspectives for the development and use of spray-dried smoke powders with improved aroma preservation and broader flavoring applications.