Formulation optimization of emulsifier-based hydrated gel cake improver for α-crystal stabilization using D-optimal...

Cake gel is widely used in bakery systems, yet its functionality declines during storage due to polymorphic transition of fat crystals from the α to β' phase. This study investigated compositional control of polymorphic stability in a distilled monoglyceride-based hydrated gel using a D-optimal mixture design. Polyglycerol ester (0-10%) and polysorbate 80 (0-5%) were incorporated at varying water levels and evaluated over 1, 30, and 60 days of storage. Thermal transitions were analyzed by differential scanning calorimetry and crystalline organization by X-ray diffraction. Fresh samples exhibited a coagel index close to 1 and a characteristic α-phase spacing of approximately 4.1 Å. During storage, systems lacking polyglycerol ester showed enhanced polymorphic conversion, whereas ester-enriched formulations preserved α-phase lamellar structure. Optimization identified 10% polyglycerol ester, 3.294% polysorbate 80, and 50.206% water as the optimal composition, achieving a desirability of 0.969 at day 30.