Development of 3D printed chocolate with reduced saturated fat using starch-based oleogels

Developing 3D printed chocolate with reduced saturated fat is challenge yet vital for chocolate production. Current study fabricated 3D printed chocolate with reduced saturated fat by partially replacing cocoa butter (10 %, 25 %, 50 %, and 75 %) with different starch-based oleogels. Composition and ratio of oleogels used altered the physicochemical properties of resulting reduced saturated fat chocolates. Thermal analysis indicated that substituting 10 % to 75 % of cocoa butter by oleogels led to significant decreases in melting peak temperature and enthalpy of cocoa butter, but retained two endothermic peaks of chocolate and polymorphic form V of cocoa butter. Rheological measurements revealed that reduced saturated fat chocolates exhibited declined apparent viscosity but similar shear-thinning behavior and gel structure to chocolate. Despite significant decrease in hardness, reduced saturated fat chocolates with up to 75 % cocoa butter being replaced displayed good printability. This work provides a novel approach to improve printability and health aspect of chocolate.