Functional properties of corn and corn–lentil extrudates

Optimization of the extrusion parameters for the production of lentil-quinoa extrudates enriched with pumpkin

This study aimed to develop a protein-fiber-rich extruded product based on yellow lentil, quinoa, and pumpkin flours. The final product quality is affected by formulation and extrusion parameters. Therefore, the effect of the pumpkin-flour ratio (A: 25-75%) and feed moisture content (C: 14-22%) besides barrel screw speed (B: 120-180 rpm) on the physical attributes of extrudates was investigated. Box-Behnken experimental design and stepwise-response surface method were used to analyze the effects of various process variables and ingredients on extrudates. The pumpkin-flour ratio had a significant positive correlation with bulk density (BD), water solubility index (WSI), and oil absorption index. Whereas the correlation between pumpkin-flour ratio with hardness, porosity, expansion ratio (ER), and water absorption index (WAI) was negative (P < 0.05). The feed moisture content positively affected the water activity (aw) and WAI and negatively affected the harness of samples (P < 0.05). The screw speed had a positive effect on ER, porosity, and WSI, whereas it negatively influenced the hardness, BD, and aw. By increasing the pumpkin-flour ratio, air cell size and wall thickness of samples had been decreased. The results showed that 44.2% pumpkin flour, 22% feed moisture, and 172.1 rpm screw speed gave an optimized product. There was no significant difference between predicted and experimental values (except for ER). The optimized snack was a good source of fiber (around 15%), protein (17.3%), and antioxidants (TPC = 15.28 mg GAE.g-1 and antiradical scavenging activity (DPPH) = 33.66%). The caloric value of the optimized snack was 362.6 cal.100g-1. The current formulation can be considered as the base of snack food or plant-based meat alternatives.

Novel Gluten-Free Breakfast Cereals Produced by Extrusion Cooking from Rice and Teff: Effects on Microstructural, Physical and Nutritional Properties

Current gluten-free products often have nutritional inadequacies. Teff is generating a growing interest for its excellent nutritional value. In this study, the effects of teff enrichment of extruded gluten-free breakfast cereals based on rice flour and two process parameters-feed moisture and temperature-were investigated based on their physical, microstructural and nutritional properties. The independent variables were modulated and examined by a Box-Behnken design. The incorporation of teff flour affected the sensory properties of extruded cereals, particularly lightness and crispness, with estimated linear effects of -6.91 and -8.49, respectively. The enrichment of breakfast cereals with teff flour also increased the total phenolic content and antioxidant capacity in both free and bound fractions, as well as the amount of insoluble dietary fibre. By varying all independent variables, the microstructural and physical properties of samples changed considerably. At the lowest feed moisture, wall thickness was small while showing the highest expansion. Samples with the highest teff flour addition exhibited an increased number of small pores which decreased crispness. These findings suggest that, by optimized extrusion cooking, the use of teff flour seems to be promising for the preparation of gluten-free breakfast cereals with superior nutritional properties and good structural characteristics.

Food extrusion: An advanced process for innovation and novel product development

Extrusion is a versatile process capable of producing a variety of new and novel foods and ingredients, thus increasing manufacturing opportunities. Further, it could provide nutritious, safe, sustainable, and affordable foods, especially directed at individualized consumer needs. In addition to past research efforts, more investigations should be conducted in order to refine, redesign, or develop new extrusion processing technologies. The present review highlights the current advances made in new and novel food product development by considering the extrusion process, the influencing parameters, and product characteristics and properties; the most promising extrusion processes that can be used in novel food product and ingredient development, such as extrusion cooking, hot-melt extrusion, reactive extrusion, and extrusion-based 3D printing; the possibilities of using various raw materials in relation to process and product development; and the needs for product development modeling along with extrusion process design and modeling. In correlation with extruded product development, topics that merit further investigation may include structure formation, plant and animal biopolymers functionalization, biopolymer reactions, process simulation, modeling and control, engineering and mechanical aspects of extruders, analysis of pre-processing treatments, as well as prototyping, risk analysis, safety, sensory and consumer acceptance.

Physicochemical Changes of Heat-Treated Corn Grain Used in Ruminant Nutrition

Cereal grain is processed using different combinations of heat, moisture, time, and mechanical action in order to improve its digestibility. The objective of the present research was to quantitatively represent the physicochemical properties of raw and processed starch using an in vitro methodology, as well as to describe the changes that occurred after heat treatment, such as pelleting, steam flaking, micronization, and extrusion of corn. Based on the obtained results, pelleting, steam flaking, and micronization can be considered as mild heat treatment methods, whereas extrusion proved to be a severe heat treatment method. Analysis of functional and pasting properties implied a possible interaction between the degraded components in the steam-flaked sample, as well as in the micronized sample, through to a lesser extent. Additionally, the occurrence of dextrins was noted after extrusion. The obtained results indicate the existence of significant differences in the physicochemical properties of corn starch depending on the heat treatment applied, which could possibly affect rumen starch degradation traits.

Twin-Screw Extrusion of Oat: Evolutions of Rheological Behavior, Thermal Properties and Structures of Extruded Oat in Different Extrusion Zones

Further investigation of material properties during the extrusion process is essential to achieve precise control of the quality of the extrudate. Whole oat flour was used to produce low moisture puffed samples by a twin-screw extruder. X-ray diffraction (XRD), Scanning electron microscopy (SEM), infrared spectroscopy (FTIR), thermal analysis, and rheological experiments were used to deeply characterize changes in the structure and cross-linking of oats in different extrusion zones. Results indicated that the melting region was the main region that changed oat starch, including the major transformation of oat starch crystal morphology and the significant decrease of enthalpy representing the starch pasting peak in the differential scanning calorimeter (DSC) pattern (p < 0.05). Moreover, the unstable structure of the protein increased in the barrel and then decreased significantly (p < 0.05) after being extruded through the die head. The viscosity of oats increased in the cooking zone but decreased after the melting zone. A transformation occurred from elastic-dominant behavior to viscoelastic-dominant behavior for oats in the melting zone and after being extruded. This study provides further theoretical support for the research of the change of materials during extrusion and the development of oat-based food.

Effects of particle size and moisture content of maize grits on physical properties of expanded snacks

The main aim of this research was to investigate the effects of simultaneous changing of maize grits particle size and moisture content on some physical properties and microstructure of the expanded snacks produced by an industrial single screw extruder. Maize grits with different particle sizes of 212-299, 300-474, 475-680, 681-870, 871-1,016, and 1,017-1,070 μm and various moisture contents of 15, 16, 17, and 18% were used to manufacture puffed products. The samples produced with larger particle sizes and higher moisture content exhibited lower water absorption and water solubility indices and less expansion and crispiness than other samples. As microstructure results revealed, these samples showed more uneven surface and thicker cross-section. Overall, controlling both moisture content and particle size of maize grits had significant effects on the quality of the snacks. However, the impact of changing particle size on the snack properties was greater than changing the moisture content. This research has implications in food industry in production of puffed snacks using extrusion process. The results provide practical and green methods of improving the quality of the snacks by choosing the appropriate feed particle size and moisture content. The approach introduced in this paper is easy to impediment in the food industry without the need to change extruder configuration or adding to the list of ingredients and additives.

Consumers' Sensory Perception of Food Attributes: Identifying the Ideal Formulation of Gluten- and Lactose-Free Brownie Using Sensory Methodologies

Products for consumers with special needs (celiac) and those who prefer a differentiated diet are necessary due to growing demand and a niche market to be exploited. The incorporation of other substances in the formulation of cakes requires a detailed analysis of their characteristics and sensorial attributes. However, the use of these flours may change the sensory characteristics of a product that is normally made from wheat flour. This study aimed to identify the ideal formulation of gluten- and lactose-free brownies made with rice flour and beans/lentils in consumer perception, through the combination of sensory tests. Using these data, the aim was to define recommendations for the reformulation of a product of high consumer acceptance, using easily accessible ingredients. The sensory methods used were descriptive analysis with a group of 20 trained evaluators and a group of 100 consumers evaluated through the check-all-that-apply and just-about-right questionnaire; all groups performed the acceptance test by hedonic scale. Data were analyzed using multivariate techniques and correlation matrices. The results showed that the attributes selected by the trained evaluators and consumers were sufficient to indicate that color and texture were the most striking characteristics that should be improved in brownie formulations without gluten and lactose. PRACTICAL APPLICATION: The study assumes that from the combination of sensory methods it is possible to verify the attributes that are most attractive to consumers in gluten-free and lactose-free cake formulations, using easily accessible ingredients that have technological, nutritional, and sensory quality, such as those formulated with wheat.

Physical structure and absorption properties of tailor-made porous starch granules produced by selected amylolytic enzymes

Porous starch granules (PSGs) with various pores and cavity sizes were prepared by amylolysis enzymes. The greatest hydrolysis rate on corn starch granule was observed with α-amylase, followed by gluco- and β-amylases. Temperature increase enhanced glucoamylase reaction rate more drastically than other enzyme treatments. Final hydrolysis level with glucoamylase reached to 66.9%, close to 67.5% of α-amylolysis. The α-amylase-treated PSGs displayed the greatest pore size and ratio of cavity-to-granule diameters. Gelatinization onset temperatures of PSGs increased to 72.1 (α-), 68.7 (β-), and 68.1°C (gluco-amylolysis) after 8 h; enthalpy changes of β- and gluco-amylase-treated PSGs increased to 13.4, and 13.1 J/g but α-amylase-treated one showed slightly reduced value of 8.5 J/g. Water holding capacities of PSGs were 209.7 (α-), 94.6 (β-), and 133.8% (gluco-amylolysis), and the untreated control had 89.1%; oil holding capacities of them showed 304.5, 182.7, and 211.5%, respectively, while the untreated control had 161.8%. Thus, enzyme types and their reaction conditions can be applied to generate desirable cavity and pore sizes in starch granules. This biocatalytic approach could contribute to develop tailor-made PSGs with distinct internal structure for specific uses in wide range of food, pharmaceutical and other industrial applications.

Application of genetic algorithm to optimize extrusion condition for soy-based meat analogue texturization

The aim of this study was to find the optimum extrusion process conditions for texturized soybean meal as a meat analogue for food formulations using genetic algorithm. The defatted soybean meal was replaced with whole soybean meal at 10% and extruded in the temperature range of 150-200 °C, screw speed of 270-300 rpm and 20-25% feed moisture content based on the Box-Behnken design. The barrel temperature effect was markedly greater than those of the feed moisture content and screw speed on the product functional properties and appearance. Higher temperatures led to a higher rehydration capacity, water and oil absorption capacity, however, it had a negative effect on the product brightness. It was found that the extrusion at lower moisture content improved soy protein functionality. Genetic algorithm technique was applied to find the best process conditions. The optimized process conditions were found to be the temperature of 198.8 °C, screw speed of 291 rpm and feed moisture content of 20.2%. Overall, the whole soybean treatment was applicable to overcome the oil separation issue during extrusion and the process was optimized to produce texturized soy protein with the maximum attainable functionality.

Techno-functional characterization of salad dressing emulsions supplemented with pea, lentil and chickpea flours

BACKGROUND

Salad dressings supplemented with pulse flours are novel products. A three-factor face-centered central composite design (CCD) was used to determine the effect of pulse flour concentration (3.5%, 7%, 10.5% w/w), egg yolk concentration (3%, 5%, 7% w/w) and oil concentration (20%, 35%, 50% w/w) on the rheological and color characteristics of salad dressings supplemented with pulse flours.

RESULTS

The consistency coefficient m, plateau modulus G(N)(0), recoverable strain Q(t) and color values were all affected by the concentrations of pulse flours used. Scanning electron microscopy showed that dressings with lower oil and egg yolk contents had a less densely packed network compared with dressings with higher oil and egg yolk contents. Sensory results were most promising for salad dressings supplemented with the whole green lentil, yellow pea with low flour content, and chickpea with high oil content.

CONCLUSION

This study should be useful for designing novel types of salad dressings to meet market requirements as well as helping to increase pulse consumption.

'The effect of inulin addition on structural and textural properties of extruded products under several extrusion conditions': The effect of inulin addition on structural and textural properties of rice flour extrudates

The growing consumer demand for healthy snacks has turned the interest of industry and research in the development of new ready-to-eat products, enriched with dietary fibers. Inulin is a soluble fiber with a neutral taste that promotes the good function of the intestine. Rice flour extrudates were produced under various extrusion temperatures, screw speeds, feed moisture concentrations and inulin replacement levels. The objective of this study was to investigate the effect of the material characteristics and the extrusion conditions on the structural and textural properties of the extrudates. Simple mathematical models were used for properties correlation with process conditions and through regression analysis it was revealed that there is a significant effect of extrusion temperature, screw speed, feed moisture content and inulin concentration on the final properties. Both density and maximum stress increased when moisture content and inulin concentration increased, while they decreased when extrusion temperature and screw speed increased. These results were also strengthened by scanning electron microscopy. The highest expansion ratio was presented when decreasing all process conditions apart from screw speed.

Investigation of functional properties and color changes of corn extrudates enriched with broccoli or olive paste

Following the tendency of replacing common food snacks with healthier food products, extruded snacks with corn flour and broccoli (4-10%) or olive paste (4-8%) were investigated in this study. The effect of material characteristics, including feed moisture content (14-19%), and broccoli or olive paste concentration, and extrusion conditions, including screw speed (150-250 r/min), and extrusion temperature (140-180 ℃), on the functional properties (water absorption index, water solubility index, and oil absorption index), as well as color change (ΔE) of the extruded snacks was studied. Regression analysis showed that screw speed did not significantly influence (p > 0.05) the properties. After mathematical modelling it was found that broccoli and olive paste concentration, as well as temperature increment, caused a decrease in water absorption index (minimum of 5.6 and 6.4 g/g sample, respectively) and an increase in water solubility index (maximum of 18.7 and 10.9 g/100 g sample, respectively), while feed moisture presented opposite tendency. Higher extrusion temperature led to an increment of oil absorption index (approximately to 1.2 and 1 mL/g sample) and decrement of color changes. Finally, feed moisture and broccoli concentration lowered oil absorption index and color of corn/broccoli extrudates, while olive paste concentration caused their increment.

Antioxidant potential and quality characteristics of vegetable-enriched corn-based extruded snacks

Phenolic content, antioxidant activity and sensory characteristics of vegetable-enriched extrudates were investigated as a result of extrusion conditions, including extrusion temperature (140-180 °C), screw rotation speed (150-250 rpm) and feed moisture content (14-19 % w.b.). Broccoli flour and olive paste was used in mixtures with corn flour at a ratio of 4 to 10 % (broccoli/corn) and 4 to 8 % (olive paste/corn). A simple power model was developed for the prediction of phenolic content and antioxidant activity of extrudates by extrusion conditions and feed composition. Phenolic content and antioxidant activity of broccoli enriched extrudates increased with extrusion temperature and broccoli addition and decreased with feed moisture content. The antioxidant activity of olive paste extrudates increased with material ratio and decreased with feed moisture content and screw rotation. Sensory porosity, homogenous structure, crispness, cohesiveness and melting decreased with feed moisture content, while the latter increased the mealy flavor and hardness of extrudates. Acceptable snacks containing broccoli flour or olive paste can be produced by selecting the appropriate process conditions.

Effect of banana flour, screw speed and temperature on extrusion behaviour of corn extrudates

Effect of extrusion parameters (banana flour, screw speed, extrusion temperature) on extrusion behaviour of corn grit extrudates were studied. Second order quadratic equations for extrusion properties as function of banana flour (BF), screwspeed (SS) and extrusion temperature (ET) were computed. BF had predominant effect on the Hunter color (L*, a*, b*) parameters of the extrudates. Addition of BF resulted in corn extrudates with higher L* and lower a* and b* values. Higher ET resulted in dark colored extrudates with lower L* and a* value. Higher SS enhanced the lightness of the extrudates. Expansion of the extrudates increased with increase in the level of BF and ET. WAI of the extrudates decreased with BF whereas increased with SS. However, reversed effect of BF and SS on WSI was observed. Flextural strength of the extrudates increased with increase in SS followed by BF and ET. The addition of BF and higher ET resulted in extrudates with higher oil uptake.

Effect of Frying Time and Temperature on the Functional Properties of Carrot Pomace, Pulse Powder and Rice Flour–Based Extrudates

The extrudates prepared under the optimized conditions of flour proportion (rice flour, pulse powder and carrot pomace), moisture content, screw speed and die temperature, were fried at temperatures of 170, 180, 190 and 200°C and for a time of 5, 10 and 15 s. Based on sensory characteristics, the selected product was stored for a period of 6 months in metalized polypropylene and evaluated for free fatty acid, peroxide value, hardness, crispiness, colour and beta carotene. The increase in colour L-values, b-values, oil absorption and decrease in colour a-values in carrot pomace–based rice extrudates was observed with the increase in frying temperature and time. The product obtained at 180°C for 15 s was rated better. The decrease in free fatty acid, colour L-values, b-values, crispiness and beta carotene and increase in peroxide value, hardness and colour a-values in carrot pomace–based rice extrudates was observed with the increase in storage period. However, the quantitative change in attributes suggested the acceptability of the product even after the storage of 6 month.