Expanding the Applications of High-amylose Fava Bean Starch: Optimization Strategies for Sustainable Valorization Into Aerogels

Fava bean starch (FBS), an underutilized starch with naturally high amylose content, offers promising functionality for aerogel development but remains largely unexplored. This study explores the sustainable valorization of high-amylose fava bean starch (FBS) into aerogels, focusing on optimization strategies. Isolated FBS (via alkaline wet washing) and air-classified FBS were used to fabricate aerogels, with key parameters─drying time, retrogradation time, and tunicate cellulose nanocrystal (t-CNC) loading─optimized using Box-Behnken Design and response surface methodology (RSM). A Box–Behnken Design combined with response surface methodology (RSM) identified optimal fabrication conditions (45 h drying, 5–5.5 h retrogradation, and varying t-CNC loadings). Aerogels from isolated FBS exhibited more uniform pore architecture, higher compressive strength (up to 0.20 MPa vs 0.12 MPa for nonpurified), and improved thermal stability (up to 340.87 °C vs 323.78 °C), while both retained high porosity (95.52–98.44%) and low density (0.05–0.06 g/cm3). Synchrotron-based microcomputed tomography (SR-μCT) revealed a well-organized honeycomb structure, supporting potential applications in thermal insulation and reactive fluid transport