Physicochemical and structural properties of dough and cookies formulated with Hodgsonia heteroclita oilseed cake as a functional fat replacer.

This study investigated the effects of partially replacing butter with Hodgsonia heteroclita oilseed cake (HHOC), obtained via enzyme-assisted mechanical extraction, at 0-60% (w/w) on the physicochemical, structural, and sensory properties of dough and cookies. HHOC incorporation significantly modified dough and cookie characteristics, increasing dough hardness from 0.24 to 0.61 kg and cookie hardness from 2.24 to 8.92 kg with increasing substitution level. SEM revealed progressive disruption of the protein-starch matrix, resulting in fragmented structures and increased cracking. FTIR indicated protein conformational changes characterized by reduced α-helix content and increased random coil structures, while XRD showed that composite dough relative crystallinity increased from 9.6% in control to a maximum of 23.0% at 50% HHOC. These molecular modifications were associated with increased hardness and fracture distance of cookies. Sensory evaluation demonstrated that up to 50% HHOC substitution maintained overall acceptability comparable to the control. The findings demonstrate that HHOC can serve as a sustainable fat replacer, by altering matrix organization and texture development while enabling substantial butter reduction without compromising consumer acceptability.