European Journal of Nutrition & Food Safety

Malting is a sustainable bioprocess that induces significant structural and biochemical modifications in cereal grains, thereby enhancing their engineering functionality and nutritional quality. This study investigates the malting-driven reconfiguration of physical and proximate properties in two climate-resilient millets, finger millet (Eleusine coracana, GIRA-2) and kodo millet (Paspalum scrobiculatum, GPUK-3), with implications for functional food systems. Controlled malting involving steeping (8–12 h), germination (48–72 h), and kilning (50–60°C) was employed. Engineering properties including grain dimensions, bulk density, true density and porosity were evaluated, alongside proximate composition using AOAC (2019) methods. Malting significantly reduced moisture content in finger millet from 11.10 to 6.83% and in kodo millet from 11.66 to 8.50% and bulk density of finger millet from 754.2 to 720.67 kg/m³, bulk density of kodo millet from 762.75 to 723.17 kg/m³ while porosity increased in finger millet from 43 to 45% and in kodo millet from 42 to 43.47%, indicating improved hydration and processability. Nutritionally, protein content increased from 7.3 to 8.6% in finger millet; from 9.03 to 11.29% in kodo millet, accompanied by enhanced ash and fiber levels, reflecting improved mineral availability and structural polysaccharide modification. The findings demonstrate that malting acts as a transformative tool for reengineering millet grains into functionally superior ingredients. The synergistic improvement in processing characteristics and nutritional profile highlights the potential of malted millets as key components in the development of fortified, sustainable and health-oriented food systems.