Formulation and Statistical Optimization of an Iron‐Enriched Bar Using RSM : Utilizing Germinated Millets and Dried Cauliflower Leaves

ABSTRACT

Iron deficiency anemia remains a major public health concern among lactating women, highlighting the need for food‐based strategies to enhance dietary iron intake. The present study aimed to develop and optimize an iron‐enriched functional bar using germinated millets and dried cauliflower leaves through Response Surface Methodology (RSM). Eight formulations were prepared, consisting of non‐germinated (T1–T4) and germinated (GT1–GT4) variants, and evaluated for proximate composition, mineral and vitamin content, bioactive compounds, anti‐nutritional factors, textural properties, and sensory acceptability. RSM optimization identified a formulation containing 30 g sorghum, 25 g barnyard millet, and 15 g dried cauliflower leaves as optimal, yielding iron (4.48 mg/100 g), calcium (32.46 mg/100 g), vitamin C (15.34 mg/100 g), protein (7.18%), and an acceptable spread ratio (4.82). Compared with non‐germinated bars, germinated formulations showed significantly higher protein (up to 14.09 g/100 g), iron (13.01 mg/100 g), total phenolic content (154.11 mg GAE/100 mg), total flavonoid content (82.18 mg QE/100 mg), and antioxidant activity (110.21%), along with lower levels of phytates (152.11 mg phytic acid/100 g) and tannins (4.48 mg TA/100 g). Sensory evaluation indicated overall good acceptability of germinated formulations, particularly those containing moderate levels of dried cauliflower leaves. These findings suggest that germination combined with the incorporation of nutrient‐rich green leafy vegetable powders can enhance the nutritional and functional quality of millet‐based snack bars intended for vulnerable populations.