SummaryThe impact of drying and encapsulation of Bacillus sp. 63‐11 on stability and bioactive properties was explored, by using modified starch (MS) or maltodextrin (MD); via freeze drying (FD) or hot‐air drying (HD). Significantly improved viability and appearance were observed in HD‐dried cells as compared to FD. HD‐MD cells exhibited 2 log CFU higher viability, lower contamination, and deeper pigmentation than HD‐MS, and superior gastrointestinal tolerance as compared to fresh cells during storage, enhanced it's probiotic potential. HD‐MD cells also exhibited dose‐dependent antibiotic susceptibility, strong antagonistic activities and consistently high antioxidant activity, i.e., Trolox equivalent antioxidant capacity at 0.4 g/mL. Additional shelf‐life testing in five food models for 90 days revealed remarkable bio‐preservative potential, particularly in high‐fat models. The study highlights the impact on probiotic potential and bioactivity of hot air‐dried encapsulated Bacillus species.