Solid fat analogue system for processed meat products: development, structural characterization, and application in emulsified sausages

Abstract This research aimed to construct a structurally stable solid fat analogue through a composite emulsion gel to satisfy the specific sizes and shape requirements of fats in certain meat products. The incorporation of high amylose corn starch (HACS) into an SPI-KGM-κ-KC composite gel significantly enhanced the texture, strength, and stability. Optimal properties (hardness: 107.08 ± 1.28 N; springiness: 2.53 ± 0.01 mm) were achieved at 9.09% HACS, closely matching those of porcine back fat (103.75 ± 2.62 N; 2.17 ± 0.04 mm). Overall, the fat analogue showed better cohesion, and structural stability than the natural fat. However, at 15 g (HACS-3), the elasticity was compromised. Microstructure revealed that a moderate HACS content promoted a dense structure, while a high level (13.04%) caused starch aggregation and network disruption. The fat analogue with 10 g of HACS exhibited the greatest structural stability and the closest macroscopic properties to porcine back fat. The gel network effectively stabilized oils in a gel network, improving nutritional quality, flavour retention, and product stability. Finally, substituting porcine back fat with this analogue in emulsified sausages preserved the fundamental texture of emulsified sausages, reduced-fat content, and optimised the fatty acid profile.