Quality characterization, optimization and consumer acceptance of enriched gluten-free crackers through valorization of chayote tuber and sprouted paheli dal flour

Abstract

Background: With rising awareness about gluten intolerance and the growing preference for healthier snack options, there is an increasing focus on developing gluten-free bakery products using nutrient-dense alternative flours. Among these, sprouted paheli dal flour (SPDF) and chayote tuber flour (CTF) stand out as promising ingredients because of their richness in protein, fiber, and essential micronutrients. Objective: The present study aimed to formulate and optimize gluten-free crackers using composite flours made from SPDF and CTF, and to evaluate their functional, nutritional, and physicochemical properties. Methods: Twelve different flour blends were prepared by varying the proportions of SPDF and CTF (70 : 30, 65 : 35, 60 : 40, 55 : 45, and 50 : 50) following a simplex lattice mixture design. The blends were analyzed for water and oil absorption capacities, foaming ability, and other functional characteristics. The best cracker formulation was identified using Design Expert software, and its proximate composition, acid-insoluble ash, and fat acidity were determined. Results: The composite flours showed good functional performance, with water absorption capacities ranging from 86.33% to 110% and oil absorption capacities between 97.33% and 144.33%. Foaming ability improved compared to refined wheat flour. The optimized formulation, containing 61.22% CTF and 38.78% SPDF, resulted in crackers with 3.72% moisture, 2.7% ash, 11.53% fat, 2.3% fiber, 15.78% protein, and 63.97% carbohydrates. Acid-insoluble ash and fat acidity were 0.032% and 1.12% oleic acid, respectively. Overall, the developed crackers had 58% more protein, 77% higher fiber, and nearly three times the vitamin and mineral content of refined wheat flour crackers. Conclusion: The combination of sprouted paheli dal and chayote tuber flour proved effective in creating a nutritious and gluten-free cracker with improved functional qualities. These findings highlight the potential of using underutilized crops to develop healthier snack alternatives suitable for gluten-sensitive and health-conscious consumers.