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Excessive sugar consumption is a public health challenge, while waste in the agroindustry generates by-products with high nutritional value. This work unites the concepts of healthiness and upcycling with the objective of developing and characterizing formulations of dietary chocolate powders, replacing sucrose with isomalt, polydextrose and palatinose, and incorporating a blend of agro-industrial by-products (patent process). For this, four formulations were developed (one standard with sucrose - AP, and three dietary - ADI, ADP, ADPA) and processed by conventional method (Normal) and by instantaneization with grain alcohol (Instantaneous'). The physical properties of the powders, such as granulometry, wettability time, angle of repose and density, were evaluated to investigate the impact of the formulations and processes. The results showed that the instantaneization process was effective, significantly improving the handling and reconstitution properties. The agglomeration of the particles, confirmed by the increase in the average diameter, resulted in an improvement in fluidity, with a reduction in the angle of repose to the range of 'excellent fluidity', and in the wettability of all samples. The formulation with instant polydextrose (ADP') stood out with the shortest wettability time (35.34 s), while the formulation with isomalt (ADI') remained the slowest The compaction force was higher for the polydextrose formulation, indicating less tendency to block formation
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