Development and Characterization of Wheat Burger Buns Fortified with Fermented–Freeze-Dried Sesame Bran Powder: Nutritional and Sensory Evaluation

Conventional wheat flour burger buns are often energy-dense but deficient in essential nutrients. This study investigated their fortification with Fermented–Freeze-Dried Sesame Bran Powder (FFSBP), a sustainable, nutrient-rich by-product. FFSBP was produced via solid-state fermentation using Lactobacillus plantarum, followed by freeze-drying, and incorporated into refined wheat flour at 0% (control), 1%, 2%, 3%, 4%, and 5% (w/w). Proximate composition, functional properties, physical characteristics, instrumental color, bioactive content, antioxidant activity, and sensory attributes were evaluated. FFSBP significantly (p < 0.05) and dose-dependently improved nutritional quality, increasing crude protein to 13.92% (a relative increase of approximately 9% compared with the control), dietary fiber by 238% (from 0.76% to 2.57%), ash mineral content, and total phenolic/flavonoid compounds. Antioxidant activity, measured via DPPH radical scavenging, increased nearly fourfold. Instrumental color analysis revealed dose-dependent darkening of the crust and crumb, with decreased lightness (L) and increased yellowness (b). However, specific volume decreased by approximately 7% at the 5% level. Sensory evaluation showed that buns with up to 3% FFSBP maintained overall acceptability comparable to the control, benefiting from enhanced taste and odor, whereas 4–5% levels negatively impacted appearance, crumb color, and mouthfeel texture, correlating with color shifts. The results demonstrate that 3% FFSBP optimally enhances nutritional and bioactive properties without compromising sensory acceptance or physical structure.