Enhancing the Stability of Wax‐Based Oleogels Through Post‐Process Thermal Treatments: A Comparative Study of Conventional, Microwave, and Infrared Heating Techniques

Oiling out remains a major limitation affecting the storage stability of wax‐based oleogels. This study investigates the influence of post‐process thermal treatment using microwave (MW) and infrared (IR) heating on the structural and stability characteristics of sunflower wax (SFW)‐based oleogels formulated with chia seed oil (CSO) and groundnut oil (GNO) (95%–97% oil content). Compared to conventionally prepared oleogels, MW‐treated samples exhibited significantly enhanced rheological behavior, firmness, and thermal stability. The post‐process thermal treatments promoted melting followed by recrystallization, resulting in improved crystal network organization. Image analysis of polarized light micrographs using ImageJ software revealed a significant reduction in the inter‐crystalline void fraction, indicating the formation of a denser crystalline network. A reduction of approximately 66% in porosity and 65% in crystal size was observed, leading to the formation of a compact three‐dimensional network. XRD analysis further indicated orthorhombic subcell network after MW treatment. DSC thermograms showed significantly higher melting enthalpies, reflecting improved thermodynamic stability. Although higher wax concentrations improved gel strength, post‐treatment using MW was more effective in enhancing structural stability. These findings demonstrate the potential of MW‐assisted post‐processing as an efficient strategy to improve the integrity and application of SFW‐based oleogels as healthier fat replacers.