A Novel Integrated Bioprocessing Strategy for the Manufacturing of Shelf-Stable, Nutritionally Upgraded Activated Wheat: Development of a Comprehensive Protocol, In-Depth Nutritional Characterization, and Evaluation of Biofunctional Properties

Abstract

Wheat, a cornerstone of global nutrition, possesses inherent nutritional constraints primarily due to the presence of phytic acid, which significantly impedes mineral bioavailability. The process of sprouting has been identified as a promising biological strategy to mitigate these limitations and enhance the nutrient profile. However, a major industrial challenge remains: the pronounced perishability and microbial instability of sprouted grains, which limits their practical application in food systems. The principal aim of this investigation was to conceive, engineer, and rigorously validate an innovative and scalable biotechnological procedure for the generation of shelf-stable activated wheat. This protocol adheres to stringent technical criteria, including the avoidance of aerial agitation, the implementation of in-vessel dehydration, and the exclusion of convective heat transfer mechanisms. The methodology centered on the design and operational characterization of a Multi-Function Bioreactor (MFB) system. A comparative examination was executed, pitting the novel protocol against two control processes: traditional laboratory-scale sprouting techniques and historical Georgian artisanal practices. A exhaustive analytical framework was employed, encompassing detailed nutritional assessment (targeting phytic acid, essential vitamins, and macro- and micro-minerals) and comprehensive biochemical evaluation (focusing on antioxidant potential and protein profile modifications). The implemented protocol yielded a highly successful reduction of phytic acid content, exceeding 60%. Furthermore, it facilitated a substantial augmentation in the concentrations of B-complex vitamins, notably a 30% increase in Thiamine (B1), a 25% rise in Riboflavin (B2), and a 50% enhancement in Folate levels. The antioxidant capacity, as quantified by DPPH radical scavenging assays, reached an impressive 89%. Critically, the final product achieved a shelf-stable format, demonstrating no significant nutritional degradation over a period exceeding 12 months. The innovative methodology described herein effectively translates a traditional food processing concept into a sophisticated, reproducible, and industrially viable biotechnological operation. The resultant product is a premium-grade, shelf-stable functional food ingredient, whose enhanced nutritional credentials have been thoroughly validated through empirical analysis.