Evaluation of the effects of sesame-based emulgels with natural and synthetic antioxidants on the physicochemical quality attributes of fried chicken nuggets

Deep-fat frying of chicken nuggets generates harmful lipid oxidation products and excessive oil uptake, compromising nutritional quality. This study investigated sesame-based emulgels (1% or 7% w/w), with or without antioxidants (0.2% rosemary extract and 0.02% tert-butylhydroquinone (TBHQ)), as functional additives to improve the quality of fried chicken nuggets (180 °C, 3 min). Proximate analysis revealed that 7% emulgel formulations significantly increased protein content (26.96 ± 0.01 vs. 24.32 ± 0.00 g/100 g in the control; p < 0.05), whereas no statistically significant differences were observed in fat content among treatments, despite numerically higher fat values in some 7% emulgel formulations. Moisture retention improved markedly in the 7% emulgel treatments (31.52–34.69 vs. 28.52 ± 1.03 g/100 g in the control; p < 0.05), accompanied by comparable crust color with only slight numerical changes in L* values and reduced hardness. Antioxidant-fortified emulgels eliminated detectable peroxide values while maintaining thiobarbituric acid reactive substances (TBARS) below the rancidity threshold (< 1.0 mg malondialdehyde (MDA)/kg). Overall, sesame-based emulgels fortified with antioxidants improved protein content, moisture retention, texture, and oxidative stability. These findings demonstrate the potential of sesame-based emulgels as functional ingredients for improving the physicochemical quality and oxidative stability of deep-fried chicken nuggets. Emulgel reduces oil absorption and improves fried chicken nugget texture. Emulgel at 7% increased protein content of fried chicken nuggets. Natural and synthetic antioxidants enhance lipid stability and color.