Treated sorghum flours were blended with refined wheat flour (RWF) at varying substitution levels (10%–70%), including a fully substituted 100% sorghum variant. Comprehensive evaluations were conducted on flour properties (such as water absorption, pasting profile, and thermal behavior), dough rheology, and final bun quality, including texture profile, specific volume, color, moisture retention, water activity, resistant starch content, microbial stability and sensory analysis.
Both pre-treatment methods significantly modified the functional attributes of sorghum. Cold plasma treated flour exhibited superior water-holding capacity, resistant starch content and rheological behavior. Buns incorporating CP-treated flour, particularly up to 30% substitution, demonstrated improved functional properties, moisture retention, texture and overall acceptability. Substitutions up to 50% maintained favorable sensory and structural attributes, whereas 100% substitution led to increased hardness, surface cracking, and reduced consumer appeal. These findings support the application of CP-treated sorghum in gluten-reduced bakery products, though challenges remain at complete replacement. In contrast, while hydrothermal treatment also enhanced sorghum’s functionality, it was comparatively less effective in sustaining dough stability and sensory quality.
Overall, the study highlighted cold plasma technology as a sustainable and innovative approach for sorghum valorization in bakery applications. It facilitates the development of nutrient-enriched, low-gluten buns with improved functionality, contributing to the advancement of clean-label and sustainable food processing solutions.
Keywords: Sorghum, Cold plasma, Hydrothermal treatment, Functional properties, Low-gluten bun