Upcycling of Mango Pulp and By-Products into Functional Flours: Effects on Bioactive Composition and Bioaccessibility in Cupcakes

The valorization of mango pulp and processing by-products as functional ingredients requires preserving bioactive compounds while ensuring their bioaccessibility after food processing and digestion. Five mango flours derived from pulp (freeze-drying, conventional drying and foam mat drying), peel and kernels were characterized and incorporated into cupcakes at a 35% wheat flour substitution level. The flours and cupcakes were evaluated for color, phenolic compounds and isoprenoids. Additionally, the bioaccessibility of these compounds was evaluated using the standardized INFOGEST in vitro digestion model. The pulp flours showed higher carotenoid content, whereas the kernel and peel flours were richer in galloyl derivatives and flavonols. After digestion, phenolic acids and mangiferin exhibited the highest bioaccessibility, while carotenoid and tocopherol bioaccessibility was strongly influenced by the drying process, with foam mat drying showing the highest values for lipophilic compounds. Overall, the results demonstrate that the nutritional functionality of mango-derived flours depends not only on their initial bioactive composition but also on the combined effects of mango part, drying process and food matrix on compound bioaccessibility. These findings support the use of mango-derived flours as sustainable functional ingredients for bakery applications.