Emerging and conventional fat replacement and modification technologies in food processing

The escalating global burden of overweight and obesity, affecting a large proportion of adults worldwide, underscores a critical public health challenge. The causes of overweight and obesity were imbalance of diet and physical activity, which have driven the concern of mass people and food producers to lean towards low-fat alternatives and fat replacers (FRs) in food products. This review critically examines various traditional and emerging FRs, as well as advanced fat modification techniques, emphasizing their nutritional value and impact on food quality amidst dietary shifts. The protein-based fat replacers, including microparticulated whey protein concentrate (WPC), egg white protein, and plant proteins; carbohydrate-based options such as resistant starch, inulin, and Z-trim; and synthetic FRs like olestra, sobestrin, and salatrim were critically evaluated. Additionally, traditional fat modification methods (e.g., interesterification, hydrogenation, blending) and innovative technologies like 3-D printing and microencapsulation were also analyzed. The review highlights the qualitative changes in food attributed to these applications and their potential health implications. Notably, protein-based FRs have demonstrated the most significant fat replacement efficacy, while the application of synthetic FRs remains under-researched. Among fat modification techniques, oleogelation and microencapsulation are particularly advantageous for incorporating essential fatty acids such as omega-3 and omega-6. The review also critically evaluates international regulatory frameworks governing fat replacers and modified fats, emerging future technologies including precision fermentation and cultivated fats, and the major barriers to commercialization, such as technological stability, consumer acceptance, clean-label expectations, regulatory uncertainty, and economic feasibility. Overall, future progress will depend on the development of clinically validated, scalable, sustainable, and consumer-acceptable fat replacement and modification strategies supported by harmonized regulatory approaches and transparent risk communication.