Protein-encapsulated fermentation carotenoids for heat-stable natural colour

Overview

This solution is a dry, water-dispersible natural colour system under development, combining fermentation-derived carotenoids with plant-protein encapsulation. The initial focus is on bacterial astaxanthin, which provides intense orange-to-red shades but is normally limited by poor water dispersibility, oxidation, and thermal instability.

The protein matrix is designed to protect the carotenoid from heat, shear, and oxygen while making the normally lipophilic pigment easier to incorporate into water-based food systems. The output is a concentrated powder intended for low-dose addition before processing steps such as extrusion, offering a practical route to heat-stable natural colours.

The same platform could later be extended to other fermentation-derived carotenoids to broaden the available colour range.

Technical specifications

How it works:

• Astaxanthin is produced by bacterial fermentation and encapsulated within a plant-protein matrix.
• The protein carrier improves water dispersibility and acts as a physical barrier against oxidation and processing stress.
• The dry powder format supports convenient storage and low-dose addition to food matrices.

Key development activities:

• Screening of plant-protein carriers, including zein, lentil, and rice protein, and preparation of laboratory prototypes with varying protein-to-active ratios, excipients, and drying conditions.
• Characterisation of particle size, encapsulation efficiency, dispersibility, astaxanthin content, yield, and antioxidant activity.
• Heat and shear testing from 75–150°C, followed by extrusion trials in a neutral tan/beige food matrix with colour measurement (CIE Lab*, ΔE), active retention, and sensory/texture assessment.
• Scale-up to 100–200 g pilot batches, stability studies, and techno-economic modelling, including ingredient cost and inclusion rate.

Technology readiness level

The technology is at an early development stage. Laboratory prototypes are planned to validate the encapsulation approach and compare encapsulated astaxanthin with free astaxanthin for colour retention, dispersibility, and antioxidant activity.

Future validation includes pilot-scale production, extrusion testing, accelerated and ambient shelf-life studies, techno-economic assessment, and definition of the industrial scale-up and regulatory pathway.