Optimization of Foam‐Mat Dried Melon Powder Using Aquafaba as a Functional Sugar Substitute

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ABSTRACT This study aimed to optimize the foam‐mat drying process of melon pulp using aquafaba and to evaluate the usage potential of the resulting functional powder as a natural sugar substitute. Increasing drying temperature caused increasing effective moisture diffusivity and decreasing drying time, ranging from 255 min at 50°C to 135 min at 70°C. Drying curves were best described with Weibull distribution and GPR and SVR machine learning models, whereas ANN provided the highest predictive performance ( R 2 > 0.99). Total phenolic content was partially retained after drying, and antioxidant activity increased at certain temperatures, while β‐carotene showed moderate degradation. The powder produced at 60°C demonstrated the best flowability and water holding capacity (without statistically significant difference), suggesting its suitability for industrial applications. However, considering the drying time, samples dried at 70°C were chosen for use as sugar substitute. Sensory evaluation of pancakes indicated that 25% sugar replacement with melon powder achieved the highest overall acceptability, whereas higher substitution levels reduced consumer preference. The use of aquafaba as a foaming agent not only improved foam stability but also supported sustainability by valorizing a legume by‐product. In conclusion, foam‐mat drying with aquafaba provides a promising method for producing functional and sustainable melon powders with potential applications as natural sweeteners in bakery products.