Formulation and optimization of Tenebrio molitor oil emulsion based-oleogel using Response Surface Methodology (RSM) for food applications

This study highlighted the development of an emulsion-based oleogel (90% fat) based on Tenebrio molitor oil, soy lecithin and emulsifiers (DMG and OilB). The oil is rich in polyunsaturated fatty acids (76.88%) and exhibits low atherogenic (0.39) and thrombogenic (0.99) indices. The optimized emulsion-based oleogel, consisted of 20% gelling agents, 70% Tenebrio molitor oil and 10% water. In the optimized formulation, the 20% gelling phase included 1.10 g of soy lecithin, 1.24 g of DMG and 17.66 g of OilB per 100 g of mixture. This oleogel shortening demonstrated satisfactory texture (1.51 N), structure (99.58% oil holding capacity) and aspect from an organoleptic perspective, achieved through optimization using the RSM method. The shortening exhibited high oxidative stability, with an oxidative induction time of 41.42 min and an oxidative induction temperature of 182.97°C. It was subsequently employed in the formulation of other food products, such as chocolate spread and cookies. These products were also characterized in terms of visual appearance, texture and rheology. Overall, the study showed that such a nutritionally valuable and environmentally sustainable oil can serve as a substitute for butter or other saturated fats in food formulations, offering products that align with the preferences of today’s consumers. • High-quality oleogel developed using Tenebrio molitor oil rich in PUFAs • Emulsion-based Tenebrio molitor oil shortening rich in oleic and linoleic acids • RSM optimization ensured high oil holding capacity and desirable hardness • Tenebrio molitor oil is sustainable and a promising alternative to conventional fats