Response surface methodology for the optimization of process parameters during hot-air frying of chicken sausages incorporated with corn bran

Deep-fat frying is still a very popular food processing method among consumers of different age groups despite the negative health implications of consuming too much fat. However, the application of innovative frying techniques such as hot-air frying is on the rise to produce low-fat fried foods owing to its acceptable characteristics. Response surface methodology has been used to study the effects of hot-air frying temperature (HFT; 170–190 °C) and time (HFt; 15–25 minutes) on some critical quality attributes of chicken sausages incorporated with corn bran. HFT and HFt had significant (p < 0.05) effects on the moisture content, colour change, total phenolics, carotenoid contents, and chewiness of samples. Hot-air frying resulted in a significant reduction in the oil content; high retention of total phenolics, carotenoids, and dietary fiber; as well as improvement in chewiness and acceptable quality attributes. The optimum processing conditions obtained were 170 °C and 25 minutes at a desirability index of 63%. Significant (p < 0.05) differences were observed in some qualities of the optimized and control samples. The study concluded that the incorporation of corn bran into sausages using the hot-air frying process can improve the quality attributes of chicken sausages and serves as a means of value addition and waste valorisation; the hot-air frying technique could be an alternative method to produce healthier, fibre-rich and acceptable fried chicken sausages in a sustainable manner.