Zein-based ternary complex stabilized oleogels for saturated fat reduction: fabrication, characterization, and application in chocolate spread.

Solid fats in chocolate spreads contribute high levels of saturated fatty acids, posing cardiovascular health concerns. This study developed zein/sodium caseinate/soybean soluble polysaccharide ternary nanoparticle-stabilized oleogels via emulsion templating to replace butter in chocolate spreads. Increasing nanoparticle concentration (2-6 wt%) reduced droplet size (100 → 0.4 μm) and enhanced oil-binding capacity (89.5 → 99.8%), attributed to β-crystalline domains, hydrogen bonding, and interfacial layers. Oleogels showed viscoelastic solid behavior with shear-thinning and thixotropic recovery (>50%). Spreads with ≤50% oleogel substitution exhibited comparable color (ΔE < 1.4) and texture to butter controls, while improving the ΣPUFA/ΣSFA ratio (0.89 vs. 0.41 in commercial spread). Findings demonstrate protein-based oleogels as feasible fat alternatives, though long-term stability and in vivo effects need validation.