Encapsulation of lime extract from by-products in zein–pectin microparticles for gluten-free vegan pancakes

Amid rising demand for healthier and sustainable foods, this study valorised lime by-products as sources of bioactive compounds within a circular economy framework. Lime extract was encapsulated in zein–pectin microparticles using a Nano Spray Dryer (NSD) and scaled up with a Mini Spray Dryer (MSD), both yielding comparable results. The developed particles showed high encapsulation efficiency (>80%), high yield (>90%), strong antioxidant capacity (>6 mg TE per g), and quantifiable phenolics. Encapsulation improved thermal stability: while free extract lost up to 92% of phenolics after 10 minutes at 200 °C, encapsulated particles retained 52%. These microparticles were added to gluten-free, vegan pancakes, improving nutritional quality and batter consistency. After in vitro digestion, encapsulated phenolics showed at least 10% higher bioaccessibility and recovery than the free extract. Even within the pancake matrix, 60% of phenolics remained bioaccessible, with recoveries above 70%. Overall, lime by-products and spray drying effectively produced stable, functional food ingredients.