Application of cocoa fiber as a by-product of cocoa processing in pasta production

The increasing generation of agro-industrial by-products has driven the search for sustainable strategies to enhance the nutritional value of cereal-based foods. This study aimed to evaluate the effect of incorporating micronized cocoa fiber (CF), a by-product of cocoa processing, into durum wheat pasta. Pasta formulations were prepared by replacing durum wheat semolina with CF at levels of 2%, 4%, 6%, and 8%, and their processing behavior, rheological properties, chemical composition, cooking quality, bioactive compounds, color, and sensory attributes were analyzed. The incorporation of CF significantly (p < 0.05) increased water absorption of the dough and modified dough rheology. Total dietary fiber (TDF) content in pasta increased from 8.09% d.b. in the control to 15.17% d.b. in CF8, while the CF4 sample reached 11.30% d.b., corresponding to levels typical of whole-grain pasta. Protein content decreased slightly (15.44% d.b. to 14.39% d.b.), whereas ash content increased significantly (0.99% d.b. to 1.47% d.b.). Cooking time decreased, and cooking loss (CL) increased but remained below the acceptable threshold of 8%. CF enrichment significantly enhanced total phenolic content, flavonoids, and antioxidant activity, although partial reductions were observed after cooking. Color parameters shifted toward darker and reddish tones (ΔE* up to 38.89). Sensory evaluation indicated no significant reduction in overall sensory acceptability, while higher CF levels improved aroma and flavor attributes. These results demonstrate that micronized cocoa fiber can be effectively utilized to produce nutritionally enhanced pasta, offering a sustainable approach for valorizing cocoa-processing by-products in line with circular economy principles.