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Fluid-Bed Encapsulated Ingredients for Bakery, Meat, Confection & Fortified Foods

Posted by Walt Zackowitz on Jan 18, 2017

Fluid-Bed Encapsulated Ingredients for Bakery, Meat, Confection & Fortified Foods

Encapsulated ingredients produced using Fluid-Bed technology has come a long way in the 35 years that it has been available commercially.  The arsenal of coating materials has also changed significantly, from predominantly fully and partially-hydrogenated vegetable oils to a wide range of consumer-friendly hot-melt and water-soluble options.

Encapsulated Ingredients, once considered “high priced problem solvers” have become a cost-effective and mainstream tool for food formulators.  The driving forces behind the increased use of encapsulated ingredients such as is the reduction in cost, but also the consistency of performance.

Encapsulation Application in Bakery

Outside of the flavor industry which uses a wide range of encapsulation techniques, bakery was the first food application for fluid-bed encapsulated ingredients.  Encapsulated Sodium Bicarbonate, used to control chemical leavening ingredients, was created with a coating blend of vegetable oil and emulsifier that isolated the bicarbonate from moisture and acids until the dough is baked.  The coating was designed to melt-away into the dough at a specific temperature, when dough moisture was still sufficient to hydrate the bicarbonate and react with the acids to create the CO2 rise.

Since those early days, Encapsulated Sorbic acid, Encapsulated Fumaric acid, Encapsulated Sodium Diacetate and Encapsulated Vinegar powder have been utilized to extend shelf-life without reducing yeast performance. Encapsulated Sodium chloride (salt), Encapsulated Sea-salt, and Encapsulated Pretzel-salt have been used to deliver desired flavor and visual-impact without the negative properties on yeast performance or freeze temperatures.   Encapsulated Fumaric acid and Encapsulated Malic acid are also commonly used to extend shelf-life in flat-breads and tortillas by delaying pH drop that can negatively impact dough performance properties.

Encapsulation Application in Meat

Restaurant and consumer hamburger meats are often seasoned using Encapsulated Salt to prevent interaction with proteins and minimize the impact on freeze temperature of the meat.   Sausage meats can consistently achieve a safe pH level (food safety and flavor) and processing time reduced (elimination of fermentation step) by direct acidification with Encapsulated acids such as Encapsulated Citric acid, Encapsulated Lactic acid, and Encapsulated GDL added with the meat seasonings.

Encapsulation Application in Confectionary

The candy industry utilizes a range of coating technologies including multi-layer fluid-bed encapsulation to create the range of survival and release properties required for innovative release of flavors, colors and effervescent effects.  Acids, especially Encapsulated Citric acid, can be hygroscopic, so can rapidly become sticky and lose flavor impact over time.  Encapsulation can isolate flavors, colors, sweeteners, and combination ingredients to create both visual and sensory effects. Other common Encapsulated Acids used in confections include Encapsulated Malic acid, Encapsulated Tartaric acid, Encapsulated Fumaric acid, and combinations.

Encapsulation Application in Fortified Foods

 Vitamins and Minerals can impart off-flavors, can lose potency over shelf-life and can react with other ingredients in a food product.  Encapsulation can overcome many of these negative properties delivering nutritional properties to foods that consumers are willing to pay premium prices for.

The most common encapsulated vitamin­­­­­­­­­­ is Encapsulated Ascorbic Acid (Vitamin-C) which is highly unstable and reactive with moisture, heat, and oxygen.  Encapsulated Vitamin-A, Encapsulated B-Vitamins, including B1 (Thiamine Mononitrate), B2 (Riboflavin), B5 (Calcium Pantothenate), B6 (Pyridoxodine Hydrochloride), and Encapsulated Folic acid (B9), provide stable forms as well as mask off-flavors and off-odors.

The most common encapsulated minerals include Encapsulated Ferrous Fumarate, Encapsulated Ferrous Sulfate, as well as Encapsulated Zinc.

Availability of Encapsulated Ingredients

For many active ingredients, there are multiple forms available as off-the-shelf stock items.  Batch fluid-bed encapsulation allow for the cost-effective production of “customized” encapsulated ingredients that deliver custom performance to meet unique and innovative applications.

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