Encapsulated Plant Extracts as Potential Clean-Label Alternatives to Synthetic Preservatives in Carbohydrate-Based Foods: Mechanisms, Efficacy, and Industrial Prospects

Carbohydrate-based foods, including breads, noodles, cereals, and snacks, are highly susceptible to microbial spoilage and oxidative deterioration, leading to significant reliance on synthetic preservatives such as propionates, sorbates, and benzoates. Concerns about their potential health risks, environmental persistence, and negative consumer perception have intensified the search for natural, clean-label alternatives. This review aims to evaluate the potential of encapsulated plant extracts as replacements for synthetic preservatives, examining their antimicrobial mechanisms, encapsulation strategies, food applications, and industrial and regulatory considerations. Evidence from studies published between 2000 and 2025 indicates that encapsulation substantially improves stability, bioactivity, and functionality of plant bioactives, with encapsulation efficiencies commonly reaching 70% to 95%, retention of 60% to 90% phenolics, and bioaccessibility increases of up to 4-fold compared with free compounds. Applications in breads, cookies, noodles, and cereals demonstrate extended mold-free shelf life by 2 to 3 days, lipid oxidation reductions of 20% to 40%, and in several cases performance equal to or superior to synthetic preservatives. Spray drying, freeze drying, coacervation, and electrohydrodynamic techniques each offer unique benefits, while carrier materials such as maltodextrin, gum arabic, and proteins are critical for optimizing outcomes. These findings suggest that encapsulated plant extracts represent potentially credible clean-label preservation systems, as their demonstrated functional efficacy aligns with regulatory frameworks such as FDA GRAS provisions, EFSA additive lists, and Codex standards. Their dual grounding in scientific evidence and regulatory compatibility highlights their promise for industrial adoption as safe, effective, and consumer-preferred alternatives in carbohydrate-based foods. HIGHLIGHTS Encapsulated plant extracts enhance stability, bioavailability, and controlled release of bioactive compounds in carbohydrate-based foods. Applications in bread, pasta, cereals, and snacks demonstrate improved shelf life, reduced microbial spoilage, and maintained sensory quality compared with synthetic preservatives. Industrial adoption requires optimized carrier systems, scalable encapsulation technologies, regulatory compliance, and integration of sustainability principles. GRAPHICAL ABSTRACT