Matrix-specific design of food-grade probiotic microcapsules: Wall materials, scalable processing, and AI-enabled optimization.

Abstract

Microencapsulation of probiotics has been widely studied to improve microbial viability during processing and storage, but its performance in real food systems remains inconsistent because protection, controlled release, sensory acceptability, and manufacturing feasibility must be balanced simultaneously. This review examines key encapsulation techniques by linking microstructural characteristics with practical scale-up constraints. It also discusses wall materials, including polysaccharides, proteins, and prebiotic matrices, with emphasis on their interactions governing encapsulation capacity, swelling behavior, and storage stability. The review further analyzes food matrix adaptability by relating the characteristics and constraints of different food systems to probiotic protection and microcapsule performance and highlights an AI-driven optimization framework that integrates material characteristics, process parameters, food-matrix constraints, and probiotic performance within multivariable and multi-objective design. Future progress requires matrix-specific wall materials and preparation methods, regulatory compliance, scalable manufacturing, and AI-assisted optimization, thereby supporting the transition of probiotic microcapsules from laboratory prototypes to industrial production.