Ultrasound‐Mediated Process Optimization, Characterization, and Thermal Stability of Beeswax–Rice Bran Oil Oleogels: An Application in Bakery Products

The study addressed the growing demand for healthier fat alternatives by formulating rice bran oil‐based oleogels using beeswax as an organogelator. This research was conducted to optimize formulation using conventional and ultrasonication processes to enhance rheological and functional characteristics, as well as thermal stability, for the development of bakery products. The optimum conditions for conventional oleogel preparation were 10.02% beeswax, 89.99°C heating, and 5°C cooling, while ultrasonication‐assisted oleogels exhibited optimum performance at 45.45% amplitude and 10.15 min sonication time. The optimization targeted improved oil binding capacity (OBC), rheological characteristics, and textural properties of the formulated oleogel. The OBC values reached 99.39% (conventional) and 99.61% (ultrasonicated), demonstrating excellent structural stability. Moreover, ultrasonication significantly enhanced gel strength, hardness, and thermal stability (DSC analysis) without altering chemical integrity (FTIR spectral analysis). Gas chromatography (GC) indicated that the oleogels retained the unsaturated fatty acid profile of rice bran oil‐based oleogel. The application of cookies development revealed that oleogels could successfully replace saturated fats, with ultrasonicated variants offering superior texture, stability, and slightly higher hardness. Sensory evaluation demonstrated that the developed oleogels were comparable to butter‐based controls in appearance, texture, flavor, and overall acceptability, indicating their potential as a viable fat replacer in bakery products without compromising consumer perception. Overall, the study established beeswax–rice bran oil oleogels, particularly ultrasonicated formulations, as sustainable, functional, and nutritionally superior fat replacers for thermally processed foods.