Spray-dried microencapsulation stabilises heat-sensitive plant bioactives into shelf-stable, beverage-compatible powders, yet the commercial viability of optimised laboratory-scale processes is rarely evaluated. Momordica charantia L. (bitter melon), whose phenolics, flavonoids, and triterpenes exert hypoglycaemic and antioxidant activities, remains a well-characterised but under-commercialised candidate for functional beverage applications. M. charantia extract was optimised via aqueous maceration and spray-drying microencapsulation using Response Surface Methodology with a two-level full factorial design (RSM–FFD) across four factors: extraction time (30–120 min), carrier type (maltodextrin or gum arabic), carrier loading (10–15% w/v of wall material relative to the total feed solution), and inlet air temperature (140–160 °C), with DPPH radical scavenging activity and powder yield as dual responses. Both models were significant (DPPH model: R² = 0.9071, Adjusted R² = 0.7214, Predicted R² = 0.0489, p ≤ 0.047; powder yield model: R² = 0.9786, Adjusted R² = 0.9541, Predicted R² = 0.8882, p < 0.0001). At the desirability-function optimum (117.67 min, 15% maltodextrin, 140 °C), the encapsulate exhibited DPPH scavenging of 53.58 ± 1.24%, powder yield of 9.00 ± 0.45%, total phenolic content of 3.07 × 10⁻⁴ g GAE/g extract, total flavonoid content of 6.99 × 10⁻⁴ g QE/g extract, moisture content of 2.04%, and near-spherical particle morphology. A mass-balance-grounded techno-economic analysis, reflecting scale economies from laboratory to pilot production, returned unit costs of MYR 3.66/g (USD 0.78/g) at laboratory scale and MYR 1.14/g (USD 0.24/g) at pilot scale, a 3.2-fold reduction, with break-even achieved below 0.8 kg/month at MYR 8.00/g. A Gompertz diffusion model projected cumulative market revenues of MYR 0.59 to 1.67 million at year 5 within the Malaysian functional food market. By coupling process optimisation with techno-economic and market-adoption analysis, this work provides a scenario-based foundation for evaluating the commercial scale-up of M. charantia microencapsulate, aligned with SDG 3 (Good Health and Well-being).