Growing consumer interest in health and sustainability has intensified the demand for effective fat replacers in the food sector. Silkworm (Bombyx mori) protein (BMP), which possesses a favorable amino acid composition, high digestibility, and relativ...
Growing consumer interest in health and sustainability has intensified the demand for effective fat replacers in the food sector. Silkworm (Bombyx mori) protein (BMP), which possesses a favorable amino acid composition, high digestibility, and relatively low environmental burden, also demonstrates excellent structure-forming capacity and functional properties during processing, making it a promising candidate for developing fat-replacement systems. In this study, a foam-templated oleogel was prepared by incorporating canola oil into a BMP–xanthan gum cryogel, and its feasibility as a palm oil substitute in chocolate spread formulations was assessed. Amino acid analysis revealed that BMP is rich in acidic amino acids and branched-chain amino acids (BCAAs), confirming its strong nutritional and functional potential. BMP exhibited pronounced protein aggregation near its isoelectric point (pH 4.5), with increased particle size and decreased zeta potential observed at pH 5.0. At pH 9.0, protein solubility, surface hydrophobicity, and both total and free sulfhydryl contents reached their highest levels, whereas S–S bond formation was minimized. The addition of xanthan gum increased solution viscosity, enhanced foam structural stability, and promoted the development of a denser microcellular network, thereby improving oil absorption and binding capacity at higher concentrations. In the oleogels, increasing xanthan gum levels led to proportional increases in viscoelastic moduli (G′ and G″), with all samples exhibiting predominantly elastic behavior. Firmness also increased with xanthan gum concentration, indicating improved structural stability of the oleogels. When incorporated into chocolate spreads, higher palm oil replacement ratios resulted in decreased viscosity, more pronounced shear-thinning behavior, and reduced firmness. From a nutritional perspective, increasing the oleogel content elevated the proportion of unsaturated fatty acids to 73.21% and reduced saturated fatty acids to 27.02%, significantly enhancing the nutritional profile. Sensory evaluation indicated that replacing 25% of palm oil with oleogel yielded the most favorable balance of physical stability and consumer acceptance. Overall, BMP-based foam-templated oleogels exhibit strong potential as functional and health-conscious alternatives to palm oil.