Green Optimization of Sesame Seed Oil Extraction via Pulsed Electric Field and Ultrasound Bath: Yield, Antioxidant Activity, Oxidative Stability, and Functional Food Potential

Sesame seed oil is a bioactive-rich lipid source, notable for lignans, tocopherols, and unsaturated fatty acids that underpin its antioxidant and cardioprotective properties. This study optimized two innovative, non-thermal extraction techniques-pulsed electric field (PEF) and ultrasound bath-assisted extraction (UBAE)-to maximize yield and preserve oil quality for functional food applications. A blocked definitive screening design combined with response surface methodology modeled the effects of energy power (<i>X</i>₁, 60-100%), liquid-to-solid ratio (<i>X</i>₂, 10-20 mL/g), and extraction time (<i>X</i>₃, 10-30 min) on fat content, DPPH antiradical activity, and oxidative stability indices (Conjugated Dienes, CDs/Conjugated Trienes, CTs). UBAE achieved the highest fat yield-59.0% at low energy (60%), high <i>X</i>₂ (20 mL/g), and short <i>X</i>₃ (10 min)-while PEF maximized DPPH to 36.0 μmol TEAC/kg oil at high energy (100%), moderate <i>X</i>₂ (17 mL/g), and short <i>X</i>₃ (10 min). CDs were minimized to 19.78 mmol/kg (UBAE, 60%, 10 mL/g, 10 min) and CTs to 3.34 mmol/kg (UBAE, 60%, 12 mL/g, 10 min). Partial least squares analysis identified <i>X</i>₂ and <i>X</i>₃ as the most influential variables (VIP > 0.8), with energy-time interplay (<i>X</i>₁ × <i>X</i>₃) being critical for antioxidant capacity. Compared to cold-pressing and Soxhlet extraction, PEF and cold-pressing retained higher antioxidant activity (~19 μmol TEAC/kg) and oxidative stability (TBARS ≤ 0.30 mmol MDAE/kg), while Soxhlet-though yielding 55.65% fat-showed the poorest quality profile (Totox value > 560). Both non-thermal techniques can deliver bioactive-rich sesame oil with lower oxidative degradation, supporting their application in functional foods aimed at improving dietary antioxidant intake and mitigating lipid oxidation burden. PEF at high energy/short time and UBAE at low energy/short time present complementary, scalable options for producing high-value edible oils aligned with human health priorities. As a limitation, we did not directly quantify lignans or tocopherols in this study, and future work will address their measurement and bioaccessibility.