VALORIZATION OF JAND RESIDUE IN MUFFIN PREPARATION

Abstract

Millets are small, nutrient-rich cereal grains known for their drought tolerance, short growing period, and health benefits, making them a sustainable alternative to conventional cereals. The purpose of this study was to valorize fermented millet residues, a by-product of traditional millet-based alcoholic beverage production, by incorporating them into functional muffins and evaluating their physicochemical, nutritional, and sensory qualities. The residues were dried, milled, and partially substituted with wheat flour. A simple lattice design using Design Expert version 13 generated six muffin formulations with 0%, 40%, 50%, 60%, 70%, and 80% substitution levels, coded as A, B, C, D, E, and F, respectively. Proximate analysis was done for wheat flour, finger millet flour, and fermented millet residue flour. Prepared muffin samples were subjected to sensory evaluation, and the results were statistically analyzed using one-way ANOVA at a 5% significance level. Muffins prepared from each formulation were evaluated for physical properties and sensory characteristics. The results showed that fermented millet residue flour had higher protein, crude fiber, ash, calcium, iron, antioxidant activity, and total phenolic content compared to wheat flour. Higher substitution levels resulted in decreases in muffin weight, volume, and specific loaf volume. Sensory evaluation showed that the 40% substituted muffin (Sample B) was significantly superior among the substituted samples and was comparable to the control in taste, aroma, aftertaste, and overall acceptability. Chemical analysis indicated that the 40% fermented millet residue flour substituted muffin had higher protein, crude fiber, ash, calcium, iron, total phenolic compound, and antioxidant activity than the control muffin. Based on sensory and nutritional evaluation, the 40% fermented millet residue flour substituted muffin was selected as the best formulation. Microbiological analysis confirmed that the selected formulation remained acceptable for up to six days at room temperature in LDPE packaging of 50 μm, with no detection of coliforms, yeast, mold, or total viable count, indicating product safety without the use of artificial preservatives. This study demonstrates a sustainable approach to by-product valorization, converting fermented millet residues into nutrient rich functional bakery products, thereby contributing to waste reduction and enhanced food security.