Effects of Sodium Reduction on the Physicochemical Characteristics of Pretzel Bites

Excessive sodium intake is a global health concern that is largely driven by processed foods. This study evaluated the effects of sodium chloride (NaCl) reduction on the physicochemical properties of pretzel bites. Samples were formulated with five NaCl levels (T1 [0% reduction], T2 [15.91% reduction], T3 [29.28% reduction], T4 [40.53% reduction], T5 [50% reduction]) and assessed for moisture, color, water activity (a_w), salinity, texture profile analysis (TPA), porosity (image-based), dough volume, and pH. Findings revealed that dough moisture was significantly affected by salt concentration, though final product (baked) moisture remained unchanged. Moderate salt reductions resulted in lighter crust and crumb colors. a_w showed a significant decrease at 50% NaCl reduction, suggesting a water-binding disruption at this level. Salinity decreased proportionally to reductions in NaCl concentration. Textural parameters, including hardness and chewiness, increased with greater salt reduction, while springiness remained stable. Porosity was highest at moderate NaCl reduction levels and decreased under further reductions. During fermentation, lower NaCl concentrations resulted in increased dough volume and more rapid acidification, as evidenced by lower pH values. Overall, salt reduction affected multiple quality parameters of pretzel bites. Moderate reductions may support healthier formulations while preserving physical functionality. These findings highlight the importance of understanding salt reduction's effects on the quality of baked foods. PRACTICAL APPLICATIONS: Results showed that moderate sodium reductions produced minimal changes compared to the control (no reduction), suggesting that partial reformulation can maintain product quality while improving nutritional profiles. These findings provide a practical framework for reducing sodium in other baked products by identifying tolerance thresholds in product development, thereby supporting industry efforts to meet public health sodium-reduction targets without compromising functional quality.