Advancements in Spray‐Drying for the Microencapsulation of Fat‐Soluble Vitamins: Stability, Bioavailability, and Applications

Background: Spray‐drying is a well‐established method for producing free‐flowing microencapsulated powders, especially for fat‐soluble vitamins (FSVs) like A, D, and E. This process enhances the stability and protection of FSVs against environmental degradation. Scope and Approach: This review highlights the application of spray‐drying to encapsulate FSVs, focusing on their role in maintaining stability, controlled release, and protection under various conditions. Current challenges and future directions in spray‐drying‐assisted encapsulation of single and multiple FSVs (like vitamin K) are also discussed. Key Findings and Conclusions: Optimizing the spray‐drying technique with efficient encapsulating agents can remarkably improve the release profiles and yields of vitamin A, emphasizing tailored formulations for stability and efficacy. For vitamin D, the choice of carrier oil and wall materials has a significant impact on bioavailability, particularly in food fortification. Although there are challenges due to heat sensitivity, spray‐drying is a versatile technique to encapsulate vitamin E with high efficiency rate, desirable particle characteristics, and effective release profiles. Comicroencapsulation with bioactive compounds further enhances the stability and bioavailability of vitamins, suggesting promising applications in food fortification and health supplementation. Comparative studies between microencapsulated FSVs and their free forms revealed improved physicochemical stability and extended‐release rates in simulated gastrointestinal conditions, as well as an enhancement in nutrient retention in food products.