This study aimed to microencapsulate Lactobacillus rhamnosus (L. rhamnosus) ATCC 7469 with whey protein concentrate (WPC), maltodextrin and trehalose by spray drying and to assess the impact of microencapsulation on cell viability and the properties of the dried powders. Spray-drying conditions, including inlet air temperature, air flow rate and feed pump, were fixed as independent variables, while probiotic survival, moisture content, water activity and effective yield were established as dependent variables. The survival of encapsulated L. rhamnosus by spray drying was optimized with response surface methodology, and the stability of the powder was assessed. The optimum spray-drying conditions were an inlet air temperature, air flow rate and feed pump rate of 169 °C, 33 m3/h and 16 mL/h, respectively, survival of 70%, air aspiration of 84% and outlet air temperature of 52 °C, achieving an overall desirability of 0.96. The physicochemical and structural characteristics of the produced powder were acceptable for application with regard to residual water content, hygroscopicity, water activity, and particle size. The results indicated that a protein-trehalose-maltodextrin mixture is a good wall material to encapsulate L. rhamnosus, showing important thermal protection during the drying process and increasing survival. However, a decrease in this capacity is observed at an air outlet temperature of approximately 101 °C. The possible effects of the wall materials and the drying conditions on survival are also discussed.
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