From Encapsulation to Food Delivery: Application-Driven Design of Functional Ingredients Using Encapsulation and Coating Approaches for Future Food Systems

Abstract

Encapsulation and coating approaches have become important tools in modern food systems for improving the stability, functionality, sensory quality, processability, and controlled delivery of bioactive and sensitive food ingredients. Their widespread adoption has enabled the incorporation of functional compounds into diverse food products while enhancing product quality, shelf life, and manufacturing performance. However, successful implementation depends not only on the encapsulation or coating strategy itself but also on the interactions among ingredient properties, carrier materials, food matrices, processing conditions, storage environments, and intended release behavior. Whereas recent reviews have mainly focused on specific encapsulation methods, carrier systems, industrial implementation, sensory functions, or regulatory aspects separately, this review integrates scientific publications and patent literature to examine method and system selection from food-engineering, formulation, processing, and industrial perspectives. Conventional processing and formulation approaches, including spray drying, freeze drying, coacervation, ionic gelation, emulsion-based encapsulation, and fluidized-bed coating, remain widely used, while established carrier systems such as liposomes and cyclodextrin inclusion complexes continue to support ingredient protection and delivery. Emerging carrier systems, including nanoemulsions, nanoliposomes, lipid nanoparticles, and hybrid multilayer structures, together with fabrication methods such as electrospraying and microfluidics, provide greater control over carrier architecture and release behavior but continue to face challenges related to manufacturing scalability, production throughput, storage stability, production cost, regulatory acceptance, and validation under industrial processing conditions. Although patent activity demonstrates continuing development of processing methods and carrier designs, patent publications alone do not establish commercial manufacture, market adoption, or industrial implementation. Across food applications, encapsulation improves ingredient protection, oxidation stability, sensory quality, dispersibility, controlled release, and process compatibility. By integrating research evidence with patent literature, this review further shows that recent progress is characterized primarily by application-driven refinement of carrier systems and fabrication methods rather than replacement of established approaches. Pet food is discussed as a representative specialized food application illustrating how encapsulation and coating strategies require adaptation to product format, processing severity, storage stability, palatability, and species-specific digestive requirements. Overall, this review highlights application-oriented food-engineering principles for selecting encapsulation methods and carrier systems suitable for industrial food applications.