Comparative assessment of encapsulated essential oils through the innovative electrohydrodynamic processing and the conventional spray drying, and freeze-drying techniques

This study evaluates the encapsulation of an essential oils blend (EOB) using electrohydrodynamic processing (EHDP), spray drying, and freeze-drying techniques. EOB, comprising oregano, rosemary, hypericum, and chamomile oils, was encapsulated in a whey protein isolate-pullulan (WPI-PL) matrix. Spray drying achieved the highest encapsulation efficiency (EE > 90%) and optimal release profiles, while electrospun structures showed gradual release and better preservation. Freeze-drying exhibited the highest encapsulation yield (EY = 83.16%) but lower efficiency (~66%). The electrospun nanostructures (EHDP) had a diameter of 543.00 ± 15.86 nm, whereas spray-dried microparticles measured 4.91 ± 3.356 μm. All encapsulated structures followed a Fickian diffusion mechanism (n ≤ 0.45). This research highlights the potential of natural bioactive compounds in food applications, contributing to sustainable, synthetic-free nutrition by enhancing stability and bioactivity of essential oils through encapsulation, reducing reliance on synthetic additives, and promoting a more natural approach to modern nutrition.