Development of novel microaerogel particles from pea protein and their application as ingredient for low-saturated fat cocoa spreads

Pea protein aqueous dispersions at 18% (w/w) were subjected to thermal gelation at the isoelectric pH, followed by water-to-ethanol solvent exchange and supercritical-CO 2 drying. The obtained particles presented a size in the range of 10–50 μm and showed internal surface area (142 m 2 /g), density (0.28 g/cm 3 ) and porosity (79%) values typical of aerogels. Their SEM microstructure revealed a peculiar hierarchical structure of aggregated dried microgels. The obtained particles were thus defined pea protein microaerogel particles. One g of microaerogel particles were able to structure 1.7 g of oil, turning it in a viscoelastic material. Based on this, the microaerogel particles were used in the preparation of cocoa spreads containing sunflower oil solely as lipid phase. The spreads containing up to 2% (w/w) microaerogel particles showed rheological moduli and spreadability behaviour comparable to those of commercial spreads, along with high physical stability (oil holding capacity >96%). Despite the similar physical properties, the saturated fatty acid content of the developed spreads was up to 57% lower than that of commercial spreads. Obtained results highlight the possibility to obtain microaerogel particles from plant proteins and demonstrate their applicability as oil structuring ingredients, suitable for the design of spreads with physical properties similar to those of market products but with a healthier lipidic profile. • Pea protein microgel particles are obtained by thermal gelation at the isoelectric pH. • Microaerogel particles are produced by solvent exchange and supercritical-CO 2 -drying. • Microaerogel particles show 142 m 2 /g surface area, 0.28 g/cm³ density, 79% porosity. • One g of microaerogel particles structures 1.7 g oil into a viscoelastic gel. • Microaerogel particles can be used for low-saturated fat cocoa spread formulation.