From emulsion to 3D-structurable oleogels: A hot-air drying strategy for plant-based fat systems with high oil...

Developing structured lipid systems with high oil content and functional applicability is critical for advancing next-generation clean-label and health-oriented food products. In this study, soy protein isolate (SPI) and sodium alginate (SA) were conjugated via pH-regulated Maillard glycation and used as emulsifiers to stabilize high internal phase emulsions (HIPEs). The emulsions, containing up to 75% (v/v) soybean oil, were transformed into oleogels using a solvent-free, energy-efficient hot-air drying process. The resulting oleogels exhibited real oil contents as high as 78.3%, with well-developed weak-gel rheological behavior, excellent oil-holding capacity, and desirable textural characteristics. Notably, oleogels with 70-75% oil content showed superior structural stability under ambient storage, thermal processing, and freeze-thaw conditions. In addition, the oleogels demonstrated good spreadability and 3D printability, indicating their suitability for application in advanced food structuring. These findings provide a sustainable and scalable approach for fabricating functional oleogels through the synergistic design of glycated biopolymer emulsifiers and mild drying techniques.