Reformulation of Puff Pastry Using Oils from Agri-Food Residues, Chia, and Poppy Seeds to Produce a Functional Spanish Cake: ‘Miguelitos de la Roda’

In this study, hydrogenated fat and butter in traditional puff pastry were partially replaced with vegetable oils from seeds to evaluate their impact on the physicochemical and sensory properties of the final product. The incorporation of vegetable oils led to changes in texture, specifically reducing hardness and chewiness. These modifications influenced the sensory perception of texture in some cases. In terms of color, the addition of vegetable oils reduced luminosity in all reformulated samples compared to the control, while parameters a* and b* were affected by the pigments present in the oils. From a nutritional perspective, this reformulation proved beneficial in reducing total fat content (between 7.34% and 17.19%) and, consequently, the energy value. The inclusion of vegetable oils also led to a decrease in saturated fatty acids, particularly in samples where butter was replaced, while the PUFA content increased (for example, 39.04% in puff pastry with chia oil; 43.04% in puff pastry with poppy oil) as well as the bioactive compounds (vitamin E). Moreover, depending on the oil used, the n-6/n-3 ratio increased compared to the control samples. Regarding sensory evaluation, all reformulated samples were well accepted, with scores above 1. However, across all evaluated parameters, the control samples consistently received higher scores. In conclusion, this study highlights the potential of vegetable oils as a viable alternative to replace traditionally used fats known for their negative health effects. Additionally, the utilization of seed oils derived from agri-food waste contributes to sustainability efforts, aligning with the goals of the 2030 Agenda and promoting innovative applications in the food industry.