Optimizing viability and yield and improving stability of Gram-negative, non-spore forming plant-beneficial bacteria encapsulated by spray-drying

This study investigates methods to commercialize safer alternatives to chemical pesticides that pose risks to human safety and the environment. Spray-drying encapsulation of the plant-protective, antifungal bacterium Collimonas arenae Cal35 in in situ cross-linked alginate microcapsules (CLAMs) was optimized to minimize losses during spray-drying and maximize yield of spray-dried powder. Only inlet temperature significantly affected survival during spray-drying, while inlet temperature, spray rate, and alginate concentration significantly affected yield of spray-dried powder. Lowering inlet temperature to 95 °C provided the greatest survival during spray-drying, while increasing inlet temperature and lowering spray rate and alginate concentration produced the highest yield. Without the CLAMs formulation, Cal35 did not survive spray-drying. When Cal35 was encapsulated in CLAMs in the presence of modified starch, shelf survival was extended to 3 weeks in a low oxygen, low humidity storage environment. Cal35 retained its antifungal activity throughout spray-drying and shelf storage, supporting its potential use as a formulated biofungicide product.