Fortification of dark chocolate with co-encapsulated saffron extract and caffeine

Abstract

• Saffron extract and caffeine were co-encapsulated via complex coacervation and spray drying. • Encapsulation reduced saffron extract degradation during chocolate processing by 25%. • Co-encapsulated powders enabled controlled co-delivery in the intestine. • Fortified chocolate maintained its physicochemical and sensory properties. This study investigates the co-encapsulation of caffeine (CAF) and saffron extract (SE) using complex coacervation followed by spray drying for the fortification of dark chocolate. The spray drying process was optimized using response surface methodology (RSM), with the inulin (IN) to maltodextrin (MD) ratio (0:1, 0.5:1, 1:1) and inlet air temperature (IAT; 140, 155, 170°C) as independent variables. The highest encapsulation efficiencies (CAF: 91.5 %; SE: 81.9 %) were achieved at an IN:MD ratio of 0.5:1 and an IAT of 155°C. Fourier-transform infrared (FTIR) spectroscopy confirmed successful co-encapsulation through physical interactions, enhancing SE stability and reducing degradation during chocolate processing, from 38.7 % (free SE) to 13.7 % (co-encapsulated SE). In vitro release studies demonstrated controlled co-delivery, with an average release of 91 % in simulated intestinal fluid. Fortification with the co-encapsulated powder had minimal impact on the physicochemical, rheological, and sensory properties of chocolate, with no significant changes in Casson yield stress (6.40 Pa), viscosity (2.45 Pa·s), or texture. Sensory evaluation confirmed acceptable consumer perception, although a slight increase in grittiness was noted due to microparticle dispersion. This research highlights co-encapsulation as a promising strategy for integrating bioactive compounds into functional foods, improving stability, bioavailability, and consumer acceptance, while aligning with the principles of Iranian Traditional Medicine.

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