OPTIMIZING CAROTENOID BIGELS FOR 3D FOOD PRINTING: AN ADVANCE TOWARD PERSONALIZED AND NUTRITIONALLY ADEQUATE DIETS

This study focused on developing an optimized carotenoid-enriched bigel formulation for effective 3D printing. Four formulations were evaluated, using an agar-xanthan gum hydrogel (HG) and a beeswax-sunflower oil oleogel (OG) at three ratios (40:60, 60:40, and 80:20 OG: HG) and added of pequi carotenoid extracts (8 µg/g, extracted with acetone and [BMIM][BF4]). In formulation 1 (15% agar, 2% xanthan gum, 10% beeswax), where hydrogel was incorporated into oleogel at room temperature, exhibited high viscosity with limited flowability. Increased oleogel ratio resulted in significant dimensional printing deviations (in mm: length 6.24 ± 2.33 to 47.64 ± 2.25, width 5.33 ± 2.4 to 36.8 ± 1.83, height 5.59 ± 5.98 to -59.38 ± 5.23), while higher hydrogel concentrations led to rough surfaces and frequent nozzle blockages. In formulation 2, incorporating hydrogel at 50°C produced a homogeneous bigel, decreasing dimensional printing deviations (in mm: length 24.7 ± 0.34, width 22.63 ± 3.5, height: -30.87 ± 1.04 at 80:20 OG: HG). However, the highest oleogel concentration caused the sample to flow when the tube was inverted. Formulation 3 showed that increasing beeswax to 15% and reducing agar/xanthan gum to 5%/1% improved gelation stability, producing parts with smooth surfaces and good shape retention. Carotenoid addition slightly compromised print precision (in mm: length 7.51 ± 0.77, width 6.38 ± 1.08, height -11.84 ± 4.24 at 80% OG). In Formulation 4 (F4), the inclusion of soy lecithin stabilized print quality, yielding well-defined 3D structures with carotenoid enrichment across all ratios. According to the International Dysphagia Diet Standardization Initiative, F4 bigels met level 4 criteria for pureed, cohesive foods suitable for spoon or fork consumption, and adapted for dysphagia diets. These findings highlight the potential of carotenoid-enriched bigels for 3D food printing applications, underscoring their utility in personalized nutrition and dietary adaptations for specific health needs.