Nutritional composition, sensory acceptability and shelf-life evaluation of wheat–corn chaff composite cake

Background In many low- and middle-income countries (LMICs), like Ghana, cereal-based baked products such as cakes are widely consumed due to their affordability and convenience. However, conventional wheat-based cakes are often characterized by low micronutrient density, limiting their contribution to adequate nutrition. Objective This study aimed to develop wheat–corn chaff composite cakes and evaluate their nutritional composition, sensory acceptability, and shelf-life stability. Methods Composite cakes were produced by substituting wheat flour with 0, 10, 15, and 20% corn chaff. Proximate composition was determined using standard AOAC methods, while mineral content (iron, zinc, and magnesium) was analyzed using Atomic Absorption Spectrophotometry. Sensory evaluation was conducted among 75 panelists using a hedonic scale and Relative Importance Index. Shelf-life stability was predicted using moisture-based accelerated models. Results Incorporation of corn chaff significantly increased ash content, indicating improved mineral density, while maintaining desirable carbohydrate and protein levels. Fiber content also improved significantly from 0.58 ± 0.07 to 2.15 ± 0.12. The composite cakes provided appreciable amounts of essential minerals (Iron = 2.87 ± 0.06 mg/100 g, Zinc = 2.70 ± 0.14 mg/100 g, Magnesium = 95.0 ± 1.41 mg/100 g), demonstrating improved micronutrient composition compared to conventional wheat cake. Sensory evaluation showed significant differences among formulations ( p < 0.05), with the 10% corn chaff cake receiving the highest overall acceptability (4.933 ± 0.251). Shelf-life was slightly reduced (8 months) compared to wheat flour (10 months), likely due to higher moisture retention. Conclusion Incorporation of 10% corn chaff significantly improves the micronutrient quality of wheat-based cakes while maintaining consumer acceptability and appreciable shelf-life stability. This approach offers a practical strategy for enhancing the nutritional value of commonly consumed baked products and promoting sustainable utilization of maize by-products.