Development and Characterization of a Plant-Based Chicken Nugget Analogue Based on Extruded Sacha Inchi Cake, Textured Soy Protein, and Wheat Gluten

This study developed a chicken nugget analogue formulated with hydrated textured soy protein (HTSP), a meat analogue based on extruded Sacha Inchi cake (MASI), and hydrated gluten (HWG). Instrumental texture analysis, cooking loss and yield, water activity (aw), pH, and color measurements were used to evaluate the effects of these protein sources. An optimal formulation was established using a D-optimal mixture design combined with a desirability function, aiming to maximize the springiness index (0.69) and minimize the hue angle (83.81 °), with a commercial chicken nugget (SF) used as reference. The optimal blend (HTSP 20.75%, MASI 46.25%, and HWG 33%) achieved a desirability value of 0.71 and was experimentally validated within a 95% confidence interval. Physicochemical characterization of the optimal formulation (OF) showed moisture content of 56.04%, protein content of 12.04%, fat content of 4.46%, and carbohydrate content of 25.54%. The OF exhibited low cooking loss (6.82%), high yield (93.18%), and favorable textural properties, including hardness (6.11 N), cohesiveness (0.20), springiness index (0.33), and chewiness index (0.40 N). Color parameters were L* 68.02, a* 1.33, b* 24.35, and a hue angle of 86.87°. Compared with commercial chicken nuggets, the OF showed similar physical and nutritional characteristics but lower fat content. Sensory evaluation using check-all-that-apply (CATA) and hedonic tests (n = 70 panelists) indicated that the commercial nugget (SF) had the highest flavor and overall acceptability but was primarily associated with greasy and salty attributes. The OF nugget was positively perceived for its crispiness and breading adhesion, although a slight bitterness was reported. In contrast, the commercial vegan nugget (FF) showed the lowest acceptability due to its dry texture and low juiciness. Overall, the results highlight the potential of plant-based protein blends for developing meat analogues; however, further optimization of flavor and aroma is required. In addition, compliance with regulatory requirements for labeling, allergen disclosure, and novel-ingredient disclosure remains essential for market entry.