Optimisation of Spray Drying Parameter and Encapsulating Agents of Spray-Dried Pineapple (Ananas comosus) Powder

Introduction: Pineapple (Ananas comosus) is rich in nutrients and bioactive compounds but highly perishable. Spray drying offers a method to create shelf-stable pineapple powder, yet high-sugar juices often result in low yield and quality issues such as caking. Methods: Response surface methodology with a face-centred composite design was used to optimise inlet temperature (145–175°C), maltodextrin (15–40% w/w), and whey protein isolate (WPI, 5–15% w/w) for pineapple juice powder. Powder yield, hygroscopicity, and dissolution time were evaluated. Results: The model predicted optimal conditions at 155.63°C, 8.28 % WPI, and 31.71 % maltodextrin, corresponding to 72.83 % yield, 70.67 s dissolution, and 8.01 % hygroscopicity (desirability = 0.831). Experimental validation produced 79.12 % yield, 73.12 s dissolution, and 7.48 % hygroscopicity, confirming model accuracy (<10 % deviation). Further characterisation of the optimised product was compared with commercially available pineapple powder and formulations optimised with maximised and minimised WPI. Increased WPI concentration with maltodextrin as encapsulating agent mixture lowered water activity and increased glass transition temperature. Surface morphology analysis also showed optimised powder with higher WPI concentration exhibited smoother and rounder particles. Discussion: WPI and maltodextrin carrier agent complex had a synergistic effect on the physical properties of spray-dried pineapple powder. Maltodextrin maintained the inner matrix while WPI contributes to the formation of protein aggregates with the surface activity and filmforming ability of protein, ultimately contributing to desirable physical properties. Conclusion: Thus, a small concentration of WPI with maltodextrin at an optimal spray drying temperature produces spray-dried pineapple powder with desirable physical properties. Maltodextrin– WPI combinations synergistically improved powder physical properties and enhanced stability. This approach enhances the physical quality of spray-dried high-sugar juices, demonstrating potential for industrial application.