A processed cheese using Grana Padano and Mozzarella cheese shavings with the addition of microencapsulated chia oil and inulin was studied. After the study of microencapsulation of chia oil, 4 processed cheeses were formulated and chemically, microbiologically and sensorially analyzed. The efficiency of microencapsulation of chia oil using ionic gelation was 94.4% with the 3:1 oil:alginate ratio, with a low solubility in water (0.04%) and a particle size of ~195 μm. The formulation with inulin had a 36% fat reduction, with no sensorial differences compared to the standard formulation. Microencapsulation was able to mask the oil taste when compared to the formulation of inulin and microcapsules of chia oil and the formulation of inulin and free-chia oil. The use of Grana Padano, inulin and encapsulated chia oil gave a product with reduced fat content and high acceptability. •An alternative process for obtaining processed cheese was developed.•Processed cheese with inulin had up to 36% less fat.•Chia oil showed thermal stability when microencapsulated.•Addition of chia oil allowed the replacement of saturated by polyunsaturated fat.