Nutritional, functional, rheological and textural properties of processed pearl millet incorporated brittle crunch

The present study developed brittle crunch formulations enriched with differently processed pearl millet and evaluated the influence of grain form and processing method on its nutritional, physicochemical, functional, textural, rheological, sensory, and storage characteristics. A total of twelve formulations were prepared using roasted whole grains, germinated whole grains, non-germinated grain flour, and germinated grain flour at different incorporation levels (10% to 20%), along with jaggery control. Standard analytical techniques were used to assess the proximate composition, sugar content, physicochemical and functional properties, texture, rheology, sensory acceptability, and microbiological stability. Pearl millet incorporation improved the nutritional profile of brittle crunch by increasing protein (1.27 to 4.00%), fibre (up to 1.94%), ash (0.94 to 1.35%), and fat (0.26 to 0.70%). The processing technique had an impact on the functional characteristics, with flour-based formulations showing better capacity to absorb water and oil. Germinated and whole grain formulations produced thicker brittle whereas the flour-based brittle demonstrated greater spread ratio. All formulations had water activity below 0.75, indicating favourable conditions for ambient storage. Rheological analysis revealed higher elastic behaviour (G' > G”) in the selected formulations, while texture analysis revealed hardness ranging from 19.84 to 36.58 kgf (kilogram-force). Among all the formulations, (OGF2) 17% germinated pearl millet flour and (NGF2) 17% non-germinated grain flour attained the highest overall sensory acceptability score (7.60/9), demonstrating that moderate pearl millet incorporation optimized sensory acceptance. Overall, incorporation of processed pearl millet successfully improved nutritional value of brittle crunch without degrading physicochemical, textural, or and sensory qualities. The developed product demonstrates potential as a functional millet-based confectionery, and future studies may focus on nutritional bioavailability, consumer acceptance at large scale, packaging optimization, and commercial product development.