Spray drying of a zinc complexing agent for inhalation therapy of pulmonary fibrosis.

Pulmonary fibrosis, a disabling lung disease, results from the fibrotic transformation of lung tissue. This fibrotic transformation leads to a deterioration of lung capacity, resulting in significant respiratory distress and a reduction in overall quality of life. Currently, the frontline treatment of pulmonary fibrosis remains limited, focusing primarily on symptom relief and slowing disease progression. Bacterial infections with Pseudomonas aeruginosa are contributing to a severe progression of idiopathic pulmonary fibrosis. Phytic acid, a natural chelator of zinc, which is essential for the activation of metalloproteinase enzymes involved in pulmonary fibrosis, shows potential inhibition of LasB, a virulence factor in P. aeruginosa, and mammalian metalloproteases (MMPs). In addition, phytic acid has anti-inflammatory properties believed to result from its ability to capture free radicals, inhibit certain inflammatory enzymes and proteins, and reduce the production of inflammatory cytokines, key signaling molecules that promote inflammation. To achieve higher local concentrations in the deep lung, phytic acid was spray dried into an inhalable powder. Challenges due to its hygroscopic and low melting (25 °C) nature were mitigated by converting it to sodium phytate to improve crystallinity and powder characteristics. The addition of leucine improved aerodynamic properties and reduced agglomeration, while mannitol served as carrier matrix. Size variation was achieved by modifying process parameters and were evaluated by tools such as the Next Generation Impactor (NGI), light diffraction methods, and scanning electron microscopy (SEM). An inhibition assay for human MMP-1 (collagenase-1) and MMP-2 (gelatinase A) allowed estimation of the biological effect on tissue remodeling enzymes. The activity was also assessed with respect to inhibition of bacterial LasB. The formulated phytic acid demonstrated an IC50 of 109.7 µg/mL for LasB with viabilities > 80 % up to 188 µg/mL on A549 cells. Therefore, inhalation therapy with phytic acid-based powder shows promise as a treatment for early-stage Pseudomonas-induced pulmonary fibrosis.

Study on stability of rose anthocyanin extracts and physicochemical properties of complex with whey protein isolate after spray drying.

Pingyin rose is an edible flower rich in anthocyanins. In this study, antioxidant capacity and color were used as the main evaluation indexes to investigate the effects of common physical and chemical factors on the stability of rose anthocyanin extracts (RAEs). In addition, the physicochemical properties of the whey protein isolate (WPI)-RAEs complex after spray drying were studied. Vitamin C, temperature, and some metal ions can cause different degrees of discoloration of RAEs solution. More importantly, heat treatment, as well as most metal ions and sugars, had no significant effect on the antioxidant capacity of RAEs solution (p > 0.05). Moreover, compared to spray-dried pure WPI, the WPI-RAEs powder was delicate and uniform, and had higher particle size, bulk density, moisture activity, and better gel properties. The release rate of all WPI-RAEs sol/gel to RAEs reached about 89% in the intestinal digestion stage, but the WPI-RAEs interaction reduced the digestibility of protein in the intestinal digestion stage. We hope that this study can provide a theoretical basis for the development and utilization of WPI-RAEs as food ingredients.

An aerosol nanocomposite microparticle formulation using Rifampicin-Cyclodextrin inclusion complexes for the treatment of pulmonary diseases.

Rifampicin (RIF) is commonly used in the treatment of tuberculosis (TB), a bacterium that currently infects one fourth of the world's population. Despite the effectiveness of RIF in treating TB, current RIF treatment regimens require frequent and prolonged dosing, leading to decreased patient compliance and, ultimately, increased mortality rates. This project aims to provide an alternative to oral RIF by means of an inhalable spray-dried formulation. TB uses alveolar macrophages to hide and replicate until the cells rupture, further spreading the bacteria. Therefore, delivering RIF directly to the lungs can increase the drug concentration at the site of infection while reducing off-site side effects. Cyclodextrin (CD) was used to create a RIF-CD inclusion complex to increase RIF solubility and biodegradable RIF-loaded NP (RIF NP) were developed to provide sustained release of RIF. RIF NP and RIF-CD inclusion complex were spray dried to form a dry powder nanocomposite microparticles (nCmP) formulation (RIF-CD nCmP). RIF-CD nCmP displayed appropriate aerosol dispersion characteristics for effective deposition in the alveolar region of the lungs (4.0 µm) with a fine particle fraction of 89 %. The nCmP provided both a burst release of RIF due to the RIF-CD complex and pH-sensitive release of RIF due to the RIF NP incorporated into the formulation. RIF-CD nCmP did not adversely affect lung epithelial cell viability and RIF NP were able to effectively redisperse from the nCmP after spray drying. These results suggest that RIF-CD nCmP can successfully deliver RIF to the site of TB infection while providing both immediate and sustained release of RIF. Overall, the RIF-CD nCmP formulation has the potential to improve the efficacy for the treatment of TB.

siRNA Nanoparticle Dry Powder Formulation with High Transfection Efficiency and Pulmonary Deposition for Acute Lung Injury Treatment.

Acute lung injury (ALI) is a severe inflammatory syndrome, which was caused by diverse factors. The COVID-19 pandemic has resulted in a higher mortality rate of these conditions. Currently, effective treatments are lacking. Although siRNA nucleotide-based drugs are promising therapeutic approaches, their poor stability and inability to efficiently reach target cells limit their clinical translation. This study identified a peptide from known cell-penetrating peptides that can form an efficient anti-inflammatory complex with TNF-α siRNA, termed SAR6EW/TNF-α siRNA. This complex can effectively transport TNF-α siRNA into the cytoplasm and achieve potent gene silencing in vitro as well as in vivo. By using lactose and triarginine as coexcipients and optimizing the spray-drying process, a powder was produced with micrometer-scale spherical and porous structures, enhancing aerosol release and lung delivery efficiency. The dry powder formulation and process preserve the stability and integrity of the siRNA. When administered intratracheally to ALI model mice, the complex powder demonstrated specific pulmonary gene silencing activity and significantly reduced inflammation symptoms caused by ALI, suggesting a potential strategy for the clinical therapeutic approach of respiratory diseases.

Microencapsulation of total saponins from stem and leaf of Panax notoginseng by freeze and spray drying: Process optimization, physicochemical properties, structure, antioxidant activity, and stability.

Ginsenosides are the primary active substance in ginseng plants and have a variety of benefits. However, its light and heat stability are weak and easy to decompose. This study used gum arabic (GA) and maltodextrin (MD) as wall materials, and 1% Tween 80 was used as emulsifier. Response surface methodology was used to optimize the preparation process of total saponins in the stems-leaves of Panax notoginseng (SLPNs) (SSLP) microcapsules by spray drying and freeze drying techniques. Under optimal process conditions, the two microcapsules have better solubility and lower moisture content (MC). The color of spray-dried SSLP microcapsules was greener and bluer, and the color was brighter. In morphology, the spray-dried SSLP microcapsules were spherical with a slightly shrunk surface, whereas the freeze-dried ones were lamellar and porous. The two microcapsules have strong stability under different storage conditions and in vitro gastrointestinal digestion simulation. In addition, both microcapsules and free SSLP contained multiple ginsenosides. At the same time, both microcapsules had good free radical scavenging ability. These results indicate that the microencapsulation technology could improve the stability and bioavailability of SSLP, which is expected to provide a reference for the intensive processing of the SLPN. PRACTICAL APPLICATION: After microencapsulation, the stem and leaf extract of Panax notoginseng improved its stability and taste, which laid a foundation for making more nutritious and better tasting food of the stem and leaf of P. notoginseng.

The Application of Pinch Technology to a Novel Closed-Loop Spray Drying System with a Condenser and Reheater.

Spray drying is an energy-intensive process in industrial use, making energy recovery a critical focus for improving overall efficiency. This study investigates the potential of integrating heat-recovery systems, including an innovative air reheater, into a closed-loop spray-drying unit to maximise energy savings. Through detailed pinch analysis, the system achieved a very low approach temperature, averaging 3.48 K, which is significantly lower than that of conventional open-loop systems. The study quantifies the energy-recovery potential by demonstrating that the integration of heat-recovery components can reduce the external heating demand by up to 30%. This not only enhances heat-transfer efficiency but also lowers operational costs and reduces the system's environmental impact. The results suggest that closed-loop systems with air reheaters offer a scalable solution for improving energy efficiency across different industrial applications. The research highlights a new paradigm: focusing on latent energy within the system rather than adjusting individual operational variables.

Surface Solid Dispersion of Ketoconazole on Trehalose Dihydrate using Spray Drying to Achieve Enhanced Dissolution Rate.

Ketoconazole (K) is a poorly water-soluble drug that faces significant challenges in achieving therapeutic efficacy. This study aimed to enhance the dissolution rate of ketoconazole by depositing spray-dried ketoconazole (SK) onto the surface of ground trehalose dihydrate (T) using spray drying. Ketoconazole-trehalose surface solid dispersions (SKTs) were prepared in ratios of 1:1 (SK1T1), 1:4 (SK1T4), and 1:10 (SK1T10), and characterized them using particle size analysis, scanning electron microscopy, powder X-ray diffraction, and in vitro dissolution studies. Results showed that the dissolution rates of the dispersions were significantly higher than those of pure ketoconazole, with the 1:10 ratio showing the highest dissolution rate. The improved dissolution was attributed to the formation of a new crystalline phase and better dispersion of ketoconazole particles. These findings suggest that the surface solid dispersion approach could be a valuable method for enhancing the bioavailability of poorly water-soluble drugs.

Lactic acid fermentation improves rehydration and emulsifying properties of spray-dried egg yolk powder.

In this study, we investigated the protein structures, powder characteristics, as well as rehydration and emulsifying properties of spray-dried egg yolk powder after short-time lactic acid fermentation (3.5 h). Results indicate that fermentation improved the rehydration and emulsifying properties of yolk powder. Limosilactobacillus reuteri-fermented yolk powder exhibited better wettability due to the porous structure of particles and higher hydrophilicity. Lacticaseibacillus rhamnosus-fermented yolk powder had an enhanced coefficient of stability due to its smaller particles and higher surface charge. The higher water solubility of fermented yolk powder samples is mainly attributed to their lower hydrophobicity and higher zeta potential. The enhanced emulsifying activity of fermented yolk powder samples is primarily related to their increased ß-turn structure and better solubility. Furthermore, fermentation treatment altered powder moisture content and bulk densities, while not affecting its flow behavior and thermal stability. This study provides an effective approach to improving the quality of yolk powder.

Development and Characterization of Olaparib-Loaded Solid Self-Nanoemulsifying Drug Delivery System (S-SNEDDS) for Pharmaceutical Applications.

This study aims to enhance the solubility of Olaparib, classified as biopharmaceutical classification system (BCS) class IV due to its low solubility and bioavailability using a solid self-nanoemulsifying drug delivery system (S-SNEDDS). For this purpose, SNEDDS formulations were created using Capmul MCM as the oil, Tween 80 as the surfactant, and PEG 400 as the co-surfactant. The SNEDDS formulation containing olaparib (OLS-352), selected as the optimal formulation, showed a mean droplet size of 87.0 ± 0.4 nm and drug content of 5.53 ± 0.09%. OLS-352 also demonstrated anticancer activity against commonly studied ovarian (SK-OV-3) and breast (MCF-7) cancer cell lines. Aerosil® 200 and polyvinylpyrrolidone (PVP) K30 were selected as solid carriers, and S-SNEDDS formulations were prepared using the spray drying method. The drug concentration in S-SNEDDS showed no significant changes (98.4 ± 0.30%, 25℃) with temperature fluctuations during the 4-week period, demonstrating improved storage stability compared to liquid SNEDDS (L-SNEDDS). Dissolution tests under simulated gastric and intestinal conditions revealed enhanced drug release profiles compared to those of the raw drug. Additionally, the S-SNEDDS formulation showed a fourfold greater absorption in the Caco-2 assay than the raw drug, suggesting that S-SNEDDS could improve the oral bioavailability of poorly soluble drugs like olaparib, thus enhancing therapeutic outcomes. Furthermore, this study holds significance in crafting a potent and cost-effective pharmaceutical formulation tailored for the oral delivery of poorly soluble drugs.

Inhibition of influenza virus infection in mice by pulmonary administration of a spray dried antiviral.

Increasing resistance to antiviral drugs approved for the treatment of influenza urges the development of novel compounds. Ideally, this should be complemented by a careful consideration of the administration route. 6'siallyllactosamine-functionalized ß-cyclodextrin (CD-6'SLN) is a novel entry inhibitor that acts as a mimic of the primary attachment receptor of influenza, sialic acid. In this study, we aimed to develop a dry powder formulation of CD-6'SLN to assess its in vivo antiviral activity after administration via the pulmonary route. By means of spray drying the compound together with trileucine, a dispersion enhancer, we created a powder that retained the antiviral effect of the drug, remained stable under elevated temperature conditions and performed well in a dry powder inhaler. To test the efficacy of the dry powder drug against influenza infection in vivo, infected mice were treated with CD-6'SLN using an aerosol generator that allowed for the controlled administration of powder formulations to the lungs of mice. CD-6'SLN was effective in mitigating the course of the disease compared to the control groups, reflected by lower disease activity scores and by the prevention of virus-induced IL-6 production. Our data show that CD-6'SLN can be formulated as a stable dry powder that is suitable for use in a dry powder inhaler and is effective when administered via the pulmonary route to influenza-infected mice.

Understanding Excipient-Induced Crystallization of Spray-Dried Amorphous Solid Dispersion.

This study investigates the compatibility of excipients with the model system SDI-X and their role in the induced crystallization of the amorphous compound-X in tablet formulations. We aimed to establish a straightforward and practical screening approach for evaluating excipient-induced crystallization of SDI in tablet matrices. Three methodologies-binary powder mixture, binary compact, and bilayer tablets-were employed to qualitatively and quantitatively evaluate the recrystallization of SDI-X with various excipients under accelerated storage conditions. The results demonstrated that binary compacts, providing direct physical contact between SDI-X and excipients, are superior in reflecting realistic drug-excipient contact within pharmaceutical tablets, enabling a more accurate assessment of excipient-induced crystallization for SDI-X. In contrast, the broadly used conventional binary blends can significantly underestimate this risk due to insufficient proximity. In addition, the bilayer tablets further confirmed that crystallization initiates at the contact surface between SDI-X and the excipients. The study highlighted that not only hygroscopicity but also the type of excipient and its physical contact with SDI-X significantly influence the recrystallization extent and rate of SDI-X. Interestingly, less hygroscopic diluents such as mannitol and lactose induced much higher levels of crystallization of SDIs, contrary to expectations based on moisture content alone. This suggests that the excipient type and contact surface are more critical in inducing recrystallization than just the level of moisture. The findings emphasize the need for careful excipient selection, study design, and sample preparation to enable appropriate assessments of SDI-excipient compatibility.

Emerging encapsulation strategies for vitamin A fortification in food sector: an overview.

Micro- and nano-encapsulation techniques, such as microfluidization, spray drying, and centrifugal extrusion, have been widely utilized in various industries, including pharmaceuticals, food, cosmetics, and agriculture, to improve the stability, shelf life, and bioavailability of active ingredients, such as vitamin A. Emulsion-based delivery platforms offer feasible and appropriate alternatives for safeguarding, encapsulating, and transporting bioactive compounds. Therefore, there is a need to enrich our basic diet to prevent vitamin A deficiency within a population. This review focused on addressing vitamin A shortages, encapsulation techniques for improving the delivery of vital vitamins A and their food applications. Additionally, more studies are required to guarantee the security of nano-delivery strategies, as they proliferate in the food and beverage sector.

The use of capsicum oleoresin microparticles to mitigate hepatic damage and metabolic disorders induced by obesity.

Capsicum oleoresin has potential health benefits, particularly against obesity markers. Due to its high pungency, few studies have been done to explore the intake of this ingredient. The objective of this study was to use the Capsicum oleoresin (CO) microencapsulated into a high-fat diet to evaluate its metabolic effect on mice. Two formulation containing 15 % solids were prepared: the first (F1) with 5% CO and 95% emulsifier, and the second (F2) with 2.5% corn oil, 2.5% CO, and 95% emulsifier. These formulation were atomized in a spray dryer. Ultra-Performance Liquid Chromatography determined the capsaicin content for both formulations. Mice were divided into two groups: lean control (normocaloric AIN diet, n = 10) and high fat (HF diet: hypercaloric, n = 30), which were subdivided into three subgroups: HF control diet (n = 10); diet F1: HF + 20 % CO oleoresin microparticles (n = 10); and diet F2: HF + 20 % CO microparticles containing corn oil (n = 10). The animals treated with the microparticles showed lower glucose levels than the HF control. Mice fed with HF-containing CO microparticles had cholesterol blood levels similar to that of the lean group and lower (<100 mg/dL) than that of the HF control group (150 mg/dL). Capsicum oleoresin microparticles added to high-fat diets promoted lower weight gain and protected the liver against hepatic steatosis. Leptin levels for mice fed with HF diet plus CO microparticles averaged between 2 and 5 ng/ml, whereas the fat control group developed leptin resistance. Capsicum microparticles evidenced a protective effect against dyslipidemia compared to the fat control group, which suggests their use as a potential ingredient for the control of obesity.

Enrichment of White Chocolate with Microencapsulated ß-Carotene: Impact on Quality Characteristics and ß-Carotene Stability during Storage.

This study developed functional white chocolate enriched with free (WC-F) and encapsulated ß-carotene using whey protein isolate (WPI) and pullulan (PUL) blends through spray drying (WC-SP), freeze drying (WC-LP), and coaxial electrospinning (WC-EL). The thermal properties, rheological properties, hardness, and color of the chocolates were evaluated, and the stability of ß-carotene was monitored over 4 months at 25 °C. No significant differences were found in melting profile temperatures among samples; however, WC-LP and WC-EL exhibited higher melting energies (30.88 J/g and 16.00 J/g) compared to the control (12.42 J/g). WC-F and WC-SP showed rheological behaviors similar to those of the control, while WC-LP and WC-EL displayed altered flow characteristics. Hardness was unaffected in WC-F and WC-SP (7.77 N/mm2 and 9.36 N/mm2), increased slightly in WC-LP (10.28 N/mm2), and decreased significantly in WC-EL (5.89 N/mm2). Over storage, melting point, rheological parameters, and hardness increased slightly, while color parameters decreased. ß-carotene degradation followed a first-order reaction model, with degradation rate constants (k) of 0.0066 day-1 for WC-SP, 0.0094 day-1 for WC-LP, and 0.0080 day-1 for WC-EL, compared to 0.0164 day-1 for WC-F. WC-SP provided the best ß-carotene retention, extending the half-life period by 2 times compared to WC-F (126.04 days vs. 61.95 days). Practical implications: The findings suggest that WC-SP, with its superior ß-carotene stability, is particularly suitable for the development of functional confectionery products with extended shelf life, offering potential benefits in industrial applications where product stability is crucial. Future research directions: Further studies could explore the incorporation of additional bioactive compounds in white chocolate using similar encapsulation methods, as well as consumer acceptance and sensory evaluation of these enriched products.

Formulation and investigation of differently charged ß-cyclodextrin-based meloxicam potassium containing nasal powders.

Nasal systemic drug delivery may provide an easy way to substitute parenteral or oral dosing, however, the excipients have an important role in nasal formulations to increase the permeability of the mucosa and prolong the residence time of the drug. In this work, we aimed to produce meloxicam potassium monohydrate (MXP) containing nasal powders by a nano spray drier with the use of a neutral, an anionic and a cationic ß-cyclodextrin as permeation enhancers, and (polyvinyl)alcohol (PVA) as a water soluble polymer. The following examinations were performed in order to study the effect of the applied excipients on the nasal applicability of the formulations: laser scattering, scanning electron microscope measurement, XRPD, DSC and FTIR measurements, adhesivity, in vitro drug release and permeability tests through an artificial membrane and RPMI 2650 cells. Based on our results, spherical particles were prepared with a size of 1.89-2.21 µm in which MXP was present in an amorphous state. Secondary interactions were formed between the excipients and the drug. The charged cyclodextrin-based formulations showed significantly higher adhesive force values regardless of the presence of PVA. The drug release was fast and complete. The passive diffusion of MXP was influenced not only by the charge of the cyclodextrin, but the presence of PVA, too. The permeation of the drug was enhanced in the presence of the anionic cyclodextrin testing it on RPMI 2650 cell model.

Spray Drying of Bacterial Membrane Vesicles for Vaccine Delivery.

Extracellular vesicles are nanosized lipid-bilayered spheres secreted from every living cell and they serve physiological and pathophysiological functions. Bacterial membrane vesicles are shed from both Gram-negative and Gram-positive bacteria and harbor many virulence factors, nuclear material, polysaccharides, proteins, and antigenic determinants, which are essential for immune recognition and evasion. Hence, bacterial membrane vesicles are very promising vaccine candidates. Spray drying is a well-established pharmaceutical technique to produce inhalable dry powders with enhanced stability for formulations of vaccines. In this chapter, we illustrate general guidelines for spray drying of bacterial extracellular vesicles to improve their stability without compromising their immunogenic protective effect. We discuss some of the most important experiments to characterize the generated spray-dried bacterial membrane vesicle powder vaccine.

Effect of processing and formulation factors on Catalase activity in tablets.

The manufacturing of tablets containing biologics exposes the biologics to thermal and shear stresses, which are likely to induce structural changes (e.g., aggregation and denaturation), leading to the loss of their activity. Saccharides often act as stabilizers of proteins in formulations, yet their stabilizing ability throughout solid oral dosage processing, such as tableting, has been barely studied. This work aimed to investigate the effects of formulation and process (tableting and spray-drying) variables on catalase tablets containing dextran, mannitol, and trehalose as potential stabilizers. Non-spray-dried and spray-dried formulations were prepared and tableted (100, 200, and 400 MPa). The enzymatic activity, number of aggregates, reflecting protein aggregation and structure modifications were studied. A principal component analysis was performed to reveal underlying correlations. It was found that tableting and spray-drying had a notable negative effect on the activity and number of aggregates formed in catalase formulations. Overall, dextran and mannitol failed to preserve the catalase activity in any unit operation studied. On the other hand, trehalose was found to preserve the activity during spray-drying but not necessarily during tableting. The study demonstrated that formulation and process variables must be considered and optimized together to preserve the characteristics of catalase throughout processing.

Impact of Wall Material-to-Active Ratio in the Stability of Spray-Dried Ascorbic Acid Using Maltodextrin and Gum Arabic.

Encapsulation revolutionizes industries through enhanced stability, controlled release, and targeted performance of active ingredients. The novel aspect of this study explores the impact of the wall material-to-active (WM:A) ratio on the stability of ascorbic acid (AA) encapsulated in a maltodextrin (MD) and gum arabic (GA) blend (2:1 w/w). Microparticles were spray-dried and analyzed using SEM, TGA, DSC, thermal stability, and antioxidant activity assessments. Stability tests under different conditions revealed that a higher WM:A ratio (7:1) improved the active stability and antioxidant activity during storage, highlighting its importance in the encapsulation process. SEM analysis confirmed particles with no cracks, and the particles demonstrated excellent thermal stability up to 200 °C with minimal degradation. These findings underscore the critical role of the WM:A ratio in determining the stability of encapsulated AA within a carbohydrate matrix, offering valuable insights for advancing encapsulation technologies.

Effects of spray drying on the content of crystal proteins of Bacillus thuringiensis and the protection by organic and inorganic auxiliaries.

Spray drying is an important industrial method for the preparation of B. thuringiensis powder from fermentation liquor. The effect of spray drying on the crystal proteins, however, has not been reported in the literature so far. The present study systematically investigated the effect of inlet air temperature, outlet air temperature, atomizing air pressure and additives (including organic and inorganic auxiliaries) on the thermal destruction of crystal proteins of B. thuringiensis. The results indicated that the content of crystal proteins of B. thuringiensis powder decreased with increased inlet air temperature, outlet air temperature and atomising air pressure. The pseudo-z values for inlet air temperature, outlet air temperature and atomizing air pressure were 826.4 â„ƒ, 204.0 â„ƒ and 4.74 MPa, respectively. Among them, the outlet air temperature was a major parameter influencing the thermal destruction of crystal proteins, therefore, the decrease of the outlet air temperature was beneficial to increase the protein content in powder. Although the spray drying had an adverse effect on crystal proteins, the crystal protein content in spray-dried powder approached that in freeze-dried powder when the inlet air temperature of 165 â„ƒ, outlet air temperature of 70 â„ƒ and atomizing air pressure of 0.15 MPa were employed. The addition of some organic and inorganic auxiliaries to fermentation liquor can protect the crystal proteins from heat damage.

Optimization of spray-drying process for the microencapsulation of L. Plantarum (MCC 2974) in ultrasound hydrated finger millet milk.

Spray drying process was optimized for the development of probiotic finger millet milk powder. The independent parameters considered were inlet air temperature, maltodextrin content, and feed rate depending upon the preliminary trials. The major dependent quality parameters considered in the current work were moisture content, water activity, powder yield, encapsulation efficiency, and viability reduction. The desirability function was considered as a basis for the optimization of spray drying process. At the optimum process conditions of 151.68 °C of inlet air temperature, 100 mL/h of feed rate, and 29.32% of maltodextrin content, probiotic finger millet milk powder with 43.81% of powder yield and 84.97% of higher encapsulation efficiency could be achieved. The SEM analysis of the spray-dried powder confirmed the proper encapsulation of viable cells in the powder matrix. XRD analysis showed the amorphous powder structure suitable for other food applications. The promising results could be further utilized to produce non-dairy probiotic finger millet milk powder.