Vacuum-fried restructured seaweed-adlay chips: Nutritional profile, antioxidant activity, and acrylamide content

Seaweed and adlay are underutilized, yet nutrient-rich crops with the potential to be developed into functional snacks. Given the increasing consumer demand for nutritious snacks, the utilization of these crops represents a sustainable food innovation. This study developed vacuum-fried restructured seaweed-adlay chips using three formulations (40:60, 50:50, and 60:40 w/w) and evaluated their sensory characteristics, nutritional composition, antioxidant potential, and acrylamide content. Sixty panelists (n = 60) rated formulation 3 as the highest in taste, texture, and overall acceptability (p < 0.05). Vacuum-frying (90 °C, 65 cm Hg) reduced oil absorption while maintaining a desirable texture. A 30 g serving provides 109.5 kcal, 4.5 g total fat, 22.06 g carbohydrates, 4.2 g dietary fiber, zero sugar, and 2.3 g protein, with notable iodine (∼93.9 µg) and selenium (∼4.5 µg) content. The product meets the criteria for protein sources, being high in fiber, low in cholesterol, and free of sugar. Total phenolic content ∼15.6 mg GAE/g; 2,2-diphenyl-1-picrylhydrazyl IC₅₀ = 8.4 mg/mL. The acrylamide content (∼504 µg/kg) was below the European Union benchmark (750 µg/kg) for potato products. This study highlights the viable utilization of underutilized crops through innovative processing, aligning with sustainable development goals 2, 12, and 14.