Layer-by-layer coating of electrosprayed Bacillus coagulans using niosomes and casein/gum arabic complexes induced by ultrasound and microwave-assisted interactions

Probiotics are highly sensitive to adverse factors, so their use in many products is a serious challenge. This research aims to create layer-by-layer coatings based on niosomes and casein/gum arabic complexes to produce electrosprayed Bacillus coagulans nanoparticles. The complexes were first performed through ultrasonic pre-treatment and subsequently completed with a secondary microwave treatment (150, 350, and 550 W). The complexes formed at 350 W microwave power were validated by FTIR, revealing the highest degree of glycation and the maximum denaturation temperature (136.75 ± 1.57 °C). Nanoniosomes prepared with Span 20 and Tween 80 exhibited the highest encapsulation efficiency. Electrospraying solutions of casein/gum arabic loaded with probiotic nanoniosomes exhibited shear-thinning characteristics, with viscoelastic properties revealing that the G' exceeded the G″. Following the electrospraying, solutions of 15% casein/gum arabic containing Span 20-based nanoniosomes (97.85 ± 1.64%) exhibited the highest viability. TEM confirmed the presence of a coated structure on the probiotics. The electrosprayed probiotic nanoniosomes formulated with Span 20 and the casein/gum arabic complex exhibited the highest viability. Developing multilayer coatings on B. coagulans, along with their nanocapsules produced by electrospray at ambient temperature, presents significant opportunities to enhance the stability and utility of probiotics in both food and pharmaceutical applications.