3D Food Printing of Surimi Gels: Optimization of Printing Parameters and Textural Properties for Dysphagia-Friendly Applications.

Abstract

This study aimed to develop a dysphagia-friendly surimi gel with optimum moisture (80%-95%) and omega-3-enriched shrimp oil (5%-20%; n3SO) content via the application of 3D food printing technology. The higher printability and structural stability were noticed at 90% moisture level as observed by higher shape retention (87%) and stability (100%). Then gel printed at selected moisture content showed decreased hardness, cohesiveness, chewiness, and viscoelastic properties with increasing oil levels. Among which, 10% n3SO provides the optimal balance of softness and consumer acceptability. Viscoelastic properties also supported the textural properties, in which increasing oil levels showed reduction in elastic and loss modulus. When 3D printing parameters, including medium (MLR), coarse (CLR) and extra coarse (ECLR) layer resolutions and nozzle diameter (1.5, 2.5, and 3.5 mm), were evaluated to print the gel. In which, MLR combined with a 3.5 mm nozzle produced gels with the lowest hardness (485.56 ± 0.61 g) and expressible moisture content (4.27 ± 0.03%). The Pearson correlation analysis also concluded that the 3.5 mm provides a practical balance between printability and structural integrity (chewiness/hardness). Confocal laser scanning microscopy revealed uniform lipid and protein distribution. In addition, cooking methods also influenced gel characteristics as observed by hardness, with steaming yielding softer gels (485.56 ± 0.61 g), microwaving producing intermediate textures (496.07 ± 1.01 g), and air frying leading to firmer (624.11 ± 2.01 g) and dehydrated gels. The optimized steamed gel was classified as IDDSI Level 5 (minced and moist), indicating safe swallowing. Thus, 3D-printed surimi gel with 90% moisture and 10% n3SO achieved IDDSI Level 5, offering a nutrient-rich, dysphagia-friendly food with good printability and texture.