A Pumpkin Seed Oil and Orange Peel Flour Gelled Emulsion as a Novel Fat Replacer in English Breakfast Sausages: Effects on Composition, Quality, and Sensory Acceptance

The excessive intake of saturated and trans fats is associated with several chronic disorders. Reformulating foods to reduce total and saturated fats has therefore become a global health priority. However, the structural and sensory roles of saturated fats often hinder direct reduction. Oil structuring technologies, such as gelled emulsions, have emerged as effective strategies to replace solid fats with liquid vegetable oils, improving nutritional quality. This study evaluated the effects of partially replacing pork backfat (33% and 66%) with oil-in-water gelled emulsions prepared using pumpkin seed oil and orange peel flour (PS-GE) in English breakfast sausages. Reformulated samples exhibited higher moisture contents, whereas fat and protein levels were reduced compared with the control. Increasing the proportion of PS-GE substitution led to a progressive rise in total unsaturated fatty acids accompanied by a decrease in total saturated fatty acids. Lipid oxidation was not affected by the reformulation in raw sausages. Sensory evaluation confirmed comparable acceptability among all samples, indicating that fat replacement did not negatively influence product quality. Overall, the use of orange peel flour and pumpkin seed oil as a gelled emulsion presents a promising strategy for producing healthier English breakfast sausages with enhanced nutritional profiles and maintained technological and sensory properties.