In this study, sugarcane molasses (SCM) was pre-treated in a low-cost fermentation medium to produce probiotic biomass of Lactobacillus paracasei ssp. paracasei F19 (LPPF19) with the combination of dilution, centrifugation, and acid hydrolysis (5 molar sulfuric acid, 60 °C/2 h). Microtox analysis, inductively coupled mass spectrometry (ICP-MS), and high-performance liquid chromatography (HPLC) were used to measure the effects of SCM pretreatment on the fermentation process. The results showed that the hydrolysis of sucrose into glucose and fructose was 98%, which represented an increase of 44.4% in the initial glucose content (fermentation-limiting sugar), and harmful heavy metals, such as arsenic, cadmium, and lead, were reduced by 50.3, 60.0, and 64.3%, respectively. After pretreatment, with the supplementation of only yeast extract and salts (Na, K, Mg, and Mn), a biomass of 9.58 log CFU/mL was achieved, approximately ten times higher than that for the control medium used (MRS/DeMan, Rogosa, and Sharpe). The cost reduction achieved compared to this commercial medium was 68.7% in the laboratory and 78.9% on an industrial scale. This work demonstrated that SCM could be used in a cheaper and more effective alternative fermentation to produce LPPF19.

This work proposes a novel drying method suitable for probiotic bacteria, called flash freeze-drying (FFD), which consists of a cyclic variation in pressure (up-down) in a very short time and is applied during primary drying. The effects of three FFD temperatures (−25 °C, −15 °C, and −3 °C) on the bacterial survival and water activity of Lactobacillus acidophilus LA5 (LA), previously microencapsulated with calcium alginate and chitosan, were evaluated. The total process time was 900 min, which is 68.75% less than the usual freeze-drying (FD) time of 2880 min. After FFD, LA treated at −25 °C reached a cell viability of 89.94%, which is 2.74% higher than that obtained by FD, as well as a water activity of 0.0522, which is 55% significantly lower than that observed using FD. Likewise, this freezing temperature showed 64.72% cell viability at the end of storage (28 days/20 °C/34% relative humidity). With the experimental data, a useful mathematical model was developed to obtain the optimal FFD operating parameters to achieve the target water content in the final drying.