Sensory evaluation
Overall, Trail I consistently showed the lowest mean scores across all the parameters, especially in appearance, flavour, taste and texture. Trail IV obtained the overall mean score of 33.4±6.90 indicating enhanced sensory attributes (Table 1).
Based on the overall sensory attributes, Trail IV was the most preferred formulation, while Trail I was least accepted. These results directed us to make suggestive changes in the formulated recipe to enhances the sensory quality of the product for better consumer acceptance. The study by
Daniel and Sokale (2024) on standardized cookie recipes using healthy alternatives reported that incorporation of nutrient-rich substitutes significantly influenced sensory attributes such as appearance, flavour, taste and texture. Their findings reported that optimized formulations achieved higher acceptability scores compared to control formulations, mainly due to improved balance of ingredients and better textural characteristics developed during baking. These observations are in strong agreement with the present study, where Trail IV recorded the highest overall mean sensory score (33.4±6.90) and it is comparable to the standard product prepared, indicating a high level of consumer acceptability while Trail I showed the lowest acceptability across all parameters. Hence the trial with the least score (Trail I, II, III and V) were withdrawn among which Trail IV with highest overall mean score was selected for formulation.
Thus, the above web diagram Fig 3 shows the sensory evaluation of formulated milk and millet-based calcium rich dietary supplement (Choco chips) across three formulation which showed noticeable changes in their acceptability score. Each formulation was incorporated with a novel value-added functional ingredient, to enhance organoleptic and nutritional quality. Thus, the formulation I was developed with a pulse with high protein and calcium content, formulation II with a low-cost green leafy vegetables and formulation III with an underexploited plant seed.
The mean score of formulation I ranged between 7.37±0.83 and 7.4±0.93 for appearance, flavour, taste, texture and colour with an overall acceptability score of 39.05±4.23 which suggests that the formulation I was highly acceptable by majority of the semi trained panellists. Overall findings revealed that incorporation of value-added ingredients influenced the sensory attributes of the milk and millet-based calcium rich dietary supplement with formulation I (Choco chips) showing higher overall acceptability and further formulation I was subjected to nutrient analysis, heavy metal analysis, microbial safety and shelf-life analysis.
The one-way ANOVA for sensory evaluation Table 2 showed highly significant differences in flavour and taste among the groups, while the overall acceptability of the formulated supplement was significant at 5% level of significance. But in contrast the appearance and texture of the formulated milk and millet-based calcium rich dietary supplement did not exhibit significant differences. Further findings indicated that three different formulations had notable impact particularly on flavour, taste and overall acceptability of the formulated milk and millet-based calcium rich dietary supplement.
Table 3 shows the nutrient composition of three formulated milk and millet-based calcium rich dietary supplement (Choco chips) and it showed minimal differences in both macro and micro nutrients. Slight difference was observed among the three formulations for calcium (Formulation I was 76 mg higher than formulation II and 84 mg higher than formulation III) and iron (formulation I was 3mg higher than formulation II and 4mg higher than formulation III), while magnesium, zinc and phosphorous remained relatively consistent. Overall, the formulated supplement indicated balanced nutrient profile with very less differences across the formulation.
The analysed nutrient composition of the formulated and developed calcium rich dietary supplement (Formulation I) provided with 471 kcal/100g with protein (10.9 g), fibre (11.6 g) and high calcium (570 mg) and iron (15.9 mg) and it is evaluated for heavy metal toxicity, microbial safety and shelf-life analysis. Considering the high prevalence of inadequate calcium intake, musculoskeletal complaints and compromised bone health among garment workers, particularly women, regular consumption of the developed calcium rich dietary supplement may contribute to improved calcium intake, support bone mineralization and potentially reduce the risk of osteopenia and osteoporosis. The protein content (10.9 g/100 g) of the supplement may help maintain muscle mass and musculoskeletal function, while the iron content (15.9 mg/100 g) helps in addressing micronutrient inadequacies commonly reported among industrial workers.
Table 4 on heavy metal content for cadmium, chromium, lead and nickel was very negligible and was below the limit of quantification. Therefore, the above finding confirmed that the formulated milk and millet-based calcium rich dietary supplement does not possess any potential health risk. Copper (Cu) was detected at 4.05 mg/kg, which was within permissible limits and was considered safe, as copper is an essential trace element required for various physiological functions, including enzyme activity and iron metabolism. The observed results confirm that formulated supplement was within the permissible limit and can be considered safe for regular consumption.
The findings of the present study fall in line with the study conducted by
Chowdhury et al., (2025), which evaluated heavy metal contamination and health risk of biscuits. In their study, heavy metals were presented in small quantities in cookies (0.2 mg/kg) and dry cake (0.4 mg/kg) and it was not detected in toast and salted biscuits. For lead, the maximum permissible limit in food ranges from 0.1 to 0.2 mg/kg as it is a carcinogenic metal known to adversely affect the human brain and kidneys, but previous studies by
Karimi et al., (2023) reported lead in higher concentration than the recommended limit in some animal products.
Microbial analysis of the formulated supplement Table 5. indicated excellent hygienic quality for safety and consumption and the total plate count was reported to be <10 CFU/g, reflecting a very low microbial load. Similarly, yeast and mould counts were also <10 CFU/g, indicating minimal risk of spoilage and extended shelf stability. The presence of
Bacillus cereus and Coliform was found to be <10 CFU/g, which was well within safe limits and does not cause any risk of foodborne illness.
Salmonella was absent in 25 g of the sample, confirming that the product is microbiologically safe and free from major pathogenic bacteria.
A study by Mukherjee and Uppaluri 2025 indicated freshly prepared cookies exhibited total plate counts and yeast and mould counts below detectable limits (<10 CFU/g), showed excellent microbiological quality and safety. Similarly, research on functional and fortified cookies reported coliforms <10 CFU/g and low yeast and mould counts, assuring that such products remain within permissible safety limits and it poses minimal risk for spoilage or contamination (
Avila-Nava et al., 2022).
Vatwani and Ravat (2025) in their recent study reported no microbial growth in fortified ragi cookies during storage which falls in line with the present study and stated that the permissible microbial limit for baked products is less than 105 CFU/g confirming their microbial safety, good storage stability and suitability for consumption.
Table 6. shows the shelf-life analysis of formulated product which belongs to the category of low-moisture baked foods, which generally possess reduced water activity and limited available moisture for the growth of enteric pathogens such as
Salmonella and coliform bacteria. In low-moisture bakery products, spoilage is predominantly associated with fungal growth (yeasts and moulds) and spore-forming bacteria such as
Bacillus cereus, which can survive baking temperatures and subsequently affect product quality during the time of storage. Therefore, TPC, yeast and mould count and
Bacillus cereus were considered more relevant indicators for assessing the microbiological stability and it remained stable for 30 days as TPC, yeast and mould count and bacillus cereus were observed below detectable levels (<10 CFU/g).
Similar observations were reported in the study conducted by
Mukherjee and Uppaluri (2025) on cookie samples developed using indigenous grains of Northeast India, where the microbial count for TPC, yeast and mould,
E.
coli,
S.
aureus,
B.
cereus and
Salmonella was undetected in the cookies. This suggests that the microbial quality of cookies during storage for 60 days remained good. Another study on value-added cookies incorporated with modified rice starch reported that total plate count and fungal counts were absent or below detectable levels during the initial storage period and remained within safe limits up to 45 days of storage, confirming the shelf stability of baked products (
Muttagi and Ravindra, 2020).
Shelf life and texture of the biscuits usually depend on moisture percentage, thereby formulated supplement on shelf-life analysis Fig 4 revealed gradual changes in their physiochemical properties over the 30 days period. The moisture content on 0
th day of formulated supplement showed (3.65%) and a slight increase up to 4.21% on the 30
th day. The increase in moisture may be attributed to variations in environmental temperature during the storage. However, this increase in moisture did noy affect the texture of the formulated dietary supplement (Choco chips). Similarly, the acidity of extracted fat showed gradual increase from 0.44% at 0
th day and 0.49% by the 30
th day. A Study by
Koh et al., (2023) on moisture content of non-gluten shortbread cookies for 7 days ranged between 6.2% and 2.19% which is comparable to the findings of the present study. A lower moisture content in the formulated milk and millet-based calcium rich dietary supplement will provide a crunchy structure and a longer shelf life to the cookies. The study by
Merlino et al., (2022) reported that fat composition and baking conditions significantly influence lipid stability in cookies, where higher fat content and processing conditions can accelerate lipid oxidation and hydrolytic reactions at the time of storage.
The shelf-life study was limited to 30 days due to time constraints and an extended shelf-life study (
e.
g., 180 days or 6 months) was not carried out, limiting the evaluation of long-term storage stability of the formulated dietary supplement.