The antioxidant activity of baked foods is of utmost interest when envisioning enhancing their health benefits. Incorporating functional ingredients is challenging since their bioactivity naturally declines during baking. In this study, 3D food printing and design of experiments are employed to clarify how the antioxidant activity of cookies enriched with encapsulated polyphenols can be maximized. A synergistic effect between encapsulation, time, temperature, number of layers, and infill of the printed cookies was observed on the moisture and antioxidant activity. Four-layer cookies with 30% infill provided the highest bioactivity and phenolic content if baked for 10 min and at 180 °C. The bioacitivity and total phenolic content improved by 115% and 173%, respectively, comparing to free extract cookies.Moreover, the proper combination of the design and baking variables allowed to vary the bioactivity of cooked cookies (moisture 3–5%) between 300 and 700 μmolTR/gdry. The additive manufacture of foods with interconnected pores could accelerate baking and browning, or reduce thermal degradation. This represents a potential approach to enhance the functional and healthy properties of cookies or other thermal treated bioactive food products.
- 3D food printing