<p>Zinc is an essential micronutrient required for growth, immunity, and development, and its deficiency remains a major public health concern, particularly in children under five years of age. This study aims to improve zinc bioaccessibility in a composite flour made from wheat, Bengal gram dhal, defatted sesame, and defatted soya using a two-step processing- first, biothermal processing, which improved zinc bioaccessibility six-fold. Secondly, fortification of the processed flour with zinc to meet the recommended dietary allowances for children enhanced bioaccessibility 20-fold. These improvements were confirmed using a Caco-2 cell line model. To improve sensory attributes, the zinc-enriched flour was incorporated with ghee and spices and mechanically pressed into Ready-to-Eat, disc-shaped biscuits termed <i>Diskettes</i>. Comprehensive analyses demonstrated that Diskettes were nutritionally balanced with adequate protein, fat, and energy, and contained appreciable levels of SFA, MUFA, and PUFA. The product remained stable for up to 90 days under ambient storage and was sensorially acceptable. These findings demonstrated that a combined strategy of processing steps and fortification significantly enhances zinc bioaccessibility in cereal-based foods, and that the formulated Diskettes may serve as a promising complementary food to address zinc deficiency in children under five years of age.</p> Graphical abstract <p></p>