Optimization and Accelerated Shelf-Life Testing of Caramelized Crushed Cashew Nut Ball

Crushed cashew nuts are often simplified as a lower-grade byproduct from cashew processing that has less value in the market than whole kernels. With the same rich nutritional profile, these broken pieces can be transformed into ingredients as new products to enhance their value. This study aimed to develop a value-added product, a nutritious caramelized ball from crushed cashew nuts combined with caramel from coconut sugar and date syrup, as a healthier alternative to refined sugar. The formulation for producing caramelized crushed cashew nut ball (CCB) was optimized using response surface methodology (RSM). The shelf-life of CCB packaged in different materials, including cast polypropylene (CPP), linear low-density polyethylene (LLDPE), and metalized aluminum (MA), was also analyzed through the accelerated shelf-life test (ASLT) to determine the suitable packaging for preserving CCB quality. The CCB samples with crushed cashew nut (100-200 g), caramel sauce (50-200 g), and cooking time (1-2 min) were then evaluated for moisture content (%), water activity (aw), hardness, and overall score for consumer acceptability (n=50). The optimum conditions were identified with 2 targets, including hardness and overall acceptability score (9-point hedonic scale) obtained at crushed cashew nuts: 190 g, caramel sauce: 200 g, and cooking time: 2 min, resulting in the overall acceptability score of 6.2 and hardness of 36.03 N. The ASLT method and the Arrhenius kinetics model evaluated their acceptance score and rancidity (thiobarbituric acid reactive substances; TBARS). These factors fit the Arrhenius plots (R2>0.87) and follow the first-order kinetics model. Among tested packaging, MA enhanced the shelf-life of CCB samples based on overall sensory acceptability for 25.90 weeks and TBARS values for 26.34 weeks at 35 °C. Furthermore, predictive equations were established for the shelf-life of CCB packeged in various packaging based on storage temperature (R2 = 0.97-0.99). The developed predictive equations and degradation kinetics study results have the potential to assist in utilizing packaging based on storage conditions to maintain the eating quality and predict the expiration shelf-life of CCB samples.