Preparation of Dietary Fiber–Sucrose Cocrystallized Structured Particles for Sugar Reduction in Chocolate

Excessive sucrose intake is linked to chronic diseases, but simple reduction impairs texture and flavor, and artificial sweeteners have drawbacks. This study developed dietary fiber–sucrose cocrystallized particles to preserve sweetness and functionality. Three dietary fibers (citrus fiber, Polydextrose, and resistant dextrin) at 5–30% were cocrystallized with sucrose. Compared with physical mixtures, cocrystallization transformed sucrose crystals into irregular porous polycrystalline aggregates with reduced crystallinity. Among the tested fibers, 20% RD-based structured particles (20% RD-SUC) exhibited optimal color and solubility (complete dissolution within 30 s) compatibility. When applied as a sucrose substitute in chocolate, 20% RD-SUC maintained the stable form VI cocoa butter polymorph and showed no significant differences from full-sugar chocolate in sweetness perception efficiency or sweetness decay kinetics. The time to maximum sweetness intensity remained 15 s, achieving an effective 20% sugar reduction. This work provides a clean-label, fiber-enriched alternative for reduced-sugar chocolate and other low-sugar foods.