Formulation and Development of Nutritious Sattu-Based Cookies: A Functional Bakery Product

Abstract

This study focuses on the preparation and quality assessment of sattu cookies made from sattu flour, a traditional and nutritious ingredient derived from roasted Bengal gram and wheat. Sattu is gaining popularity in modern baking due to its health benefits and distinct nutty flavor. Incorporating sattu into cookies offers a creative way to blend wholesome nutrition with delicious taste. The process of making sattu cookies involves formulating a nutritious and flavorful cookie using sattu, a roasted gram flour rich in protein, fiber, and essential nutrients. The formulation aims to optimize the ingredient composition to achieve a balance between taste, texture, and nutritional value. Sattu is combined with whole sugar, jaggery, and fats like butter, as well as flavor enhancers such as cardamom or nuts. The mixture is then shaped into cookies and baked at a temperature of 170-180?C to create a crispy texture. The study investigated the relationship between the proportions of ingredients and their influence on the taste, texture, and aroma of the cookies. The sensory evaluation revealed a preference for Sample 5 and Sample 6, which were prepared using 5 grams of sugar and 5 grams of jaggery as sweeteners, along with milk and water, respectively. The findings suggest that specific combinations of ingredients can significantly enhance the taste and aroma of the cookies.

Introduction

The study focuses on developing nutritious sattu cookies as a healthy alternative to popular Western-style snacks, which often lack nutritional value compared to traditional Indian foods. Sattu, a roasted gram and wheat flour known for its high protein, fiber, and mineral content, is used as the primary ingredient. The research involves formulating cookies with varying proportions of sattu, jaggery, sugar, butter, and baking powder, followed by sensory and physico-chemical evaluation.

The baking process includes mixing ingredients to form dough, shaping cookies, baking at controlled temperatures, cooling, and packaging with suitable materials to maintain freshness and appeal.

Results showed that cookies with around 42% sattu, balanced sweeteners (jaggery and sugar), and sufficient butter had the best taste, texture, and nutritional profile. Cookies high in sattu were denser and grainier, while lower sattu content resulted in softer cookies. Jaggery enhanced a caramel-like flavor and aroma, favored by adult consumers, whereas children preferred sweeter, flavored variants like chocolate chip.

Physico-chemical analysis revealed low moisture content (~3.33%) ensuring crispness and good shelf life, and adequate mineral content (ash ~2.33%). Sensory testing indicated Trial 6 (with optimized ingredient levels) scored highest in taste, mouthfeel, and overall acceptance, making it the preferred formulation.

The study highlights sattu cookies as a healthy snack option bridging traditional nutrition and modern baking, appealing to diverse consumer preferences and promoting health benefits.

Conclusion

The use of convection ovens for baking cookies remains a standard method in the food processing industry due to its efficiency, energy savings, and ability to produce consistent, high-quality baked goods. In this study, sattu cookies—a nutritious alternative incorporating roasted gram flour—were developed and evaluated at various baking temperatures (165°C, 170°C, and 175°C) to determine the most suitable conditions for production. The findings revealed that higher baking temperatures contribute to increased nutritional loss, emphasizing the importance of temperature control. Based on sensory evaluation, moisture retention, and overall dough performance, it was concluded that a baking temperature range of 170–175°C is optimal for producing sattu cookies with desirable texture, flavor, and shelf stability. Furthermore, the low moisture content (3.33%) achieved in the final product suggests excellent potential for extended shelf life. The absence of coliform bacteria and controlled microbial growth indicate good hygienic quality of the cookies. However, the impact of residual moisture on long-term storage stability warrants further investigation. Future research will focus on the storage behavior and shelf life of sattu cookies under varying packaging conditions and environmental factors.

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Copyright

Copyright © 2025 Lilesh H. Pustode, Prashant S. Watkar, Shivani S. Palawar, Manju S. Nishad, Aishwarya V. Khobragade. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.