Physically modified and polyphenol complexed kodo millet starch as a fat replacer in egg-free mayonnaise

Abstract Mayonnaise is the most popular and widely liked oil-in-water type emulsion food. Due to the growing demand for reduced-fat and healthier mayonnaise, the focus shifted to developing reduced-fat and egg-free mayonnaise using physically modified (annealing, heat, moisture, and ultrasonication) and quercetin-complexed Kodo millet starch. The prepared starches were incorporated as fat replacers in mayonnaise formulations, with full-fat mayonnaise serving as the control. Comprehensive analyses were conducted to evaluate structural, functional, and sensory attributes. The results indicated that the reduced-fat mayonnaise had significantly lower fat content (18.482–19.697 %) and calorific value, with increased moisture and carbohydrate levels compared to the control. Heat-moisture-treated starch-quercetin complex demonstrated superior emulsion stability, improved rheological consistency, and desirable textural properties, while maintaining high sensory acceptance and also conferring enhanced nutritional benefits. These findings highlight the potential of modified-complexed starches as fat replacers for producing nutritionally enhanced, low-fat, and egg-free mayonnaise.