Enhancing spray drying tolerance of Lactobacillus bulgaricus by intracellular trehalose delivery via electroporation

Spray-drying is an efficient drying technique for preparing probiotic powders, but the high temperatures employed during the process results in low survival rates of lactic acid bacteria. This study aimed to enhance spray-drying tolerance of lactic acid bacteria by intracellular delivery of trehalose via electroporation. Diverse electroporation conditions were applied to Lactobacillus delbrueckii ssp. bulgaricus sp1.1 cells exposed to 10% trehalose prior to spray drying with 30% re-constituted skimmed milk. Survival rates of spray-dried bacteria increased with an intracellular trehalose content of ≥3.5 µg/10⁷ colony-forming units (CFU) and reached 100% with intracellular trehalose content of 10.1 µg/10⁷ CFU. The application of two electroporation pulses at 2.5 kV/cm helped increase the survival rate of L. bulgaricus from 38% to 61% after spray drying. Membrane damage and pore formation caused by excessive pulsed electric field treatment resulted in cell death after spray drying. Sufficient intracellular trehalose protected cell walls and membranes from further damage by spray drying. Multi-pulse electroporation of trehalose into lactic acid bacteria prior to spray drying can potentially increase cell viability.