Innovative plant-based drinks produced by pulse spray drying: An approach on physicochemical properties and microbial assessment

The growing demand for sustainable and nutritious dairy alternatives has driven interest in plant-based beverages, particularly in powdered formats that enhance shelf life and transportability. This study investigated the application of Pulse Spray Drying (PSD), an emerging energy-efficient technology, for producing innovative powdered plant-based drinks. Four formulations were developed using oat flour as the base ingredient, combined with lupin flour, fava bean protein isolate (FPI), and buckwheat flour. Conventional Spray Drying (SD) was used as a benchmark for comparison. The resulting powders were evaluated for their protein content, moisture, water activity, solubility, particle size, density, flow properties, color, hydroxymethylfurfural (HMF) concentration, FTIR spectra, and microbiological quality. PSD-treated samples generally exhibited higher moisture content, larger particle sizes, and better flowability than SD-treated samples. The oat-buckwheat-FPI combination showed significant protein losses under PSD, likely due to aggregation or matrix-specific interactions during drying. In the other formulations, protein retention remained consistent. Solubility and density were formulation-dependent, particularly in samples containing FPI. Color changes were more pronounced in PSD powders, possibly linked to intensified Maillard reactions. HMF levels were low and stood within safety standards. Microbiological analyses confirmed products meet quality standards, though some indicators suggest opportunities for process refinement. FTIR spectroscopy revealed distinct structural differences between raw materials and final powders, reflecting the physicochemical changes induced by processing. The findings confirm that PSD is a promising alternative to traditional drying for producing high-protein, shelf-stable, plant-based powders. The study underscores the importance of aligning formulation design with processing conditions to optimize product quality and functionality. • Pulse Spray Drying (PSD) was used to produce plant-based protein-rich powders. • Oat, lupin, buckwheat, and fava bean protein isolate (FPI) were tested. • PSD increased moisture and particle size compared to conventional drying. • PSD improved flow properties in FPI-based powders, despite some protein loss. • FTIR confirmed structural shifts from raw materials to dried powder formulations.