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Sesame seeds are a healthy food ingredient and an oil crop for sesame oil production; however, it has recently been recognized as an essential allergenic food by FAO/WHO. This research investigated the relationship between the hot air roasting process (at 120, 150, and 180 °C for 10, 20, and 30 min) and several quality attributes of sesame seeds since roasting is the key process for preparing sesame seeds for both consumption and oil production. The hot air process followed the central composite design. The changes of sesame in terms of color, sensory properties (odor, texture, color, and taste), allergenicity caused by oleosins (ses i 4 and ses i 5), as well as oil extraction and quality were monitored using a colorimeter, sensory evaluation panelists, ELISA, as well as oil yield and acid value, respectively. Roasting temperature influenced the product quality more than roasting time, although the two processing parameters significantly interacted with each other (P < 0.001). Sensory evaluation indicated medium roasting generated attractive flavor, order, appearance, and crispy texture. Allergenicity was high in sesame seeds after high-temperature roasting, according to IgE binding capacity test. Sesame oil extraction was favored by high-temperature roasting, which, however, adversely affected the oil quality. The optimal roasting conditions were 150.5 °C for 15 min for optimized sesame seeds quality in terms of sensory properties and allergenicity, while roasting at 158 °C for 10 min was optimal for sesame oil production. The finding will benefit the sesame seed industry.

•Complicated binding modes between the proteins and polyphenols should be noted.•Protein structural alterations and polyphenols functions lead to allergy reduction.•Factors on allergenic protein-plant polyphenol complexes are reviewed.