Development of chitosan-based oleogels via crosslinking with vanillin using an emulsion templated approach: Structural characterization and their application as fat-replacer

In this study, we aimed to develop chitosan-based oleogels via crosslinking with vanillin using an emulsion-templated approach to allow the physical trapping of oil in the chitosan matrix. The role of Tween®60 to modulate the gelled network strength and the use of oleogels as a shortening substitute in cookies was also investigated. Four oleogels were structured using 0.75% chitosan by emulsion templates exclusively when vanillin was used (1.0% or 3.0%), resulting in a network able to entrap oil via the formation of Schiff bases with chitosan. All chitosan-oleogels presented adequate moisture (<3%), lipid content (>92%), high thermostability and moderate oil binding capacity (OBC). At 3.0% vanillin, the chitosan-oleogel displayed a more open microstructure and resulted in a weaker gel (↓G′) with lower OBC and mechanical resistance than the chitosan-oleogel with 1.0% vanillin. Tween®60 led to unstable oleogels during shearing, despite their higher hardness and adhesiveness due to a more compact microstructure. Chitosan-oleogel with 1.0% vanillin (without Tween®60) exhibited the best performance as a shortening substitute in cookies. Therefore, the emulsion-templated approach combined with the crosslinking modification of chitosan by vanillin enabled chitosan to form an edible oleogel to provide processed foods that are trans -fat-free with potential health-promoting properties. • Chitosan crosslinked with vanillin structured oleogels by emulsion-template approach. • Chitosan-oleogels show good mechanical strength, shear-thinning behavior and high thermostability. • Strength of oleogels was influenced by vanillin and Tween®60 contents. • Chitosan oleogel with 1.0% vanillin stood out as solid fat replacer in cookies.