Design of apple snacks – A study of the impact of calcium impregnation method on physicochemical properties and structure of apple tissues during convective drying

Calcium impregnation methods (at atmospheric pressure, AI, or under vacuum, VI) followed by air drying at 60 °C were used for producing healthy apple snacks. This study compared the effect of the impregnation method on the ultrastructure features and physicochemical properties (desorption isotherm, density, porosity and shrinkage, thermal transitions, rheological behaviour, colour) of fortified apples along convective drying. Calcium concentration in AI and VI dried apples were ≈ 3600 and ≈ 5200 ppm respectively, which implied, considering a portion of dried apple of 50 g, 18% and 26% of the recommended intake for adults. Calcium incorporation did not affect the desorption behaviour but induced browning of apple tissues. Drying resulted in a great increase in porosity of AI samples and a noticeable compaction of the VI tissues. Impregnated tissues at aw ≤ 0.47 exhibited distinctive mechanical properties: AI apples were characterized by very high stiffness and lower resistance to rupture, while VI apples appeared stronger and moderately stiff. This study will help to develop large-scale commercial production of calcium fortified apple snacks with distinctive characteristics. High quality and content of nutrients, easy industrialization and storage and a long shelf life are important aspects of these healthy snacks. They constitute a valuable functional shelf-stable product, that also can help feeding the population during natural disasters and wars, as well as reducing food insecurity in vulnerable groups as part of the diet. On the other hand, the use of apples not meeting the organoleptic requirements for direct consumption, or not processed into juice, drink, or cider as raw material, looks of particular interest for diversifying the production within the framework of sustainable production. •Healthy apple snacks can be formulated by calcium impregnation before drying step.•Calcium impregnation method affects apple structure and physicochemical properties.•Calcium incorporation induces browning of dried apple.•Calcium do not modify apple desorption isotherms but changes glass transition.