Mathematical modeling of flow behavior and cell structure formation during extrusion of starchy melts

Sugar inclusion influences the expansion characteristics of corn starch extrudates

Corn starch-based direct expanded products incorporated with 2% and 10% (w/w) sugar (fructose, glucose, sucrose, and xylose) were produced using a 20 mm co-rotating twin-screw extruder. The pasting and thermal properties of raw corn starch-sugar mixes were analyzed before extrusion processing. The independent variables for extrusion processing included two sugar inclusion levels (2% and 10% w/w) and two screw speeds (150 and 250 rpm). The extrudates were characterized by their initial expansion ratio (IER), expansion ratio (ER), and shrinkage. ER values were high for fructose at 2% and 150 rpm and 10% glucose and sucrose extrudates at 250 rpm. The extrudates with 2% sucrose inclusion shrunk significantly higher than the control. Fourier transform infrared (FTIR) spectroscopy of the extruded blends did not indicate the presence of any new covalent bond formed between starch and sugar post-extrusion. The interactions between sugar concentration and screw speed significantly influenced extrudate expansion characteristics. Due to their thermal and plasticizing properties, sugar inclusion (glucose, fructose, sucrose, and xylose) enhanced the extrudate expansion by altering their melt viscosity. PRACTICAL APPLICATION: The findings of this study can improve the expansion characteristics of high-fiber-based extruded snacks. Ingredients high in fiber generally hinder the starch transformation during extrusion and negatively impact the expansion properties. The presence of sugar at low concentrations can improve melt properties during extrusion processing and, in turn, significantly improve the textural properties of snacks.

High methoxyl pectin can improve the extrusion characteristics and increase the dietary fiber content of starch-cellulose extrudates

Improving total dietary fiber content while maintaining the texture/expansion of extruded products is a challenge. Pectin has a dual function; it is a source of dietary fiber and it also functions as a hydrocolloid, which could improve the texture of high-fiber extruded foods. The objective of this study was to evaluate the impacts of pectin types from citrus peel on the expansion characteristics of starch-cellulose extrudates. High and low methoxyl pectin (HMP and LMP) was added to the starch-cellulose mixtures and extruded using a twin-screw extruder. The pasting properties of raw mixtures, extrusion properties, microstructure, and dietary fiber contents of the extrudates were studied. The inclusion of HMP in raw material improved the peak viscosity (629.7 ± 8.1 to 754.7 ± 80.1 mPa s) and maintained the final viscosity compared to the control (starch-cellulose mixture alone), unlike LMP. HMP relatively maintained the extrusion process parameters such as torque, back pressure, and specific mechanical energy as the control. Interestingly, the addition of 7% of HMP had a similar expansion ratio (3.41 ± 0.08 to 2.35 ± 0.06) compared to the control (3.46 ± 0.08 to 2.32 ± 0.09) under the extrusion conditions studied. The total dietary fiber content improved from 12.22 ± 0.01% to 18.26 ± 0.63% (w/w). HMP maintained the expansion characteristic of starch-cellulose extrudates and improved its total dietary fiber content relative to LMP. Adding HMP to the mixtures improved the extensibility of the melt, favoring bubble growth and expansion of the starch-cellulose extrudates. Fourier transform infrared spectroscopy data suggested that there could be intermolecular interactions between starch, cellulose, and pectin, but the nature of these interactions needs further investigation. PRACTICAL APPLICATION: The study provides practical information on the influence of the addition of high and low methoxyl pectin on starch-cellulose extrudates. The results can help the industry to produce snack products that are more nutritious but are still well accepted by the consumers.

Modeling and Simulation of 3D Food Printing Systems-Scope, Advances, and Challenges

Food 3D printing is a computer-aided additive manufacturing technology that can transform foods into intricate customized forms. In the past decade, this field has phenomenally advanced and one pressing need is the development of strategies to support process optimization. Among different approaches, a range of modeling methods have been explored to simulate 3D printing processes. This review details the concepts of various modeling techniques considered for simulating 3D printing processes and their application range. Most modeling studies majorly focus on predicting the mechanical behavior of the material supply, modifying the internal texture of printed constructs, and assessing the post-printing stability. The approach can also be used to simulate the dynamics of 3D printing processes, in turn, assisting the design of 3D printers based on material composition, properties, and printing conditions. While most existing works are associated with extrusion-based 3D printing, this article presents scope for expanding avenues with prominent research and commercial interest. The article concludes with challenges and research needs, emphasizing opportunities for computational and data-driven dynamic simulation approaches for multi-faceted applications.

Modelling Volume Change and Deformation in Food Products/Processes: An Overview

Volume change and large deformation occur in different solid and semi-solid foods during processing, e.g., shrinkage of fruits and vegetables during drying and of meat during cooking, swelling of grains during hydration, and expansion of dough during baking and of snacks during extrusion and puffing. In addition, food is broken down during oral processing. Such phenomena are the result of complex and dynamic relationships between composition and structure of foods, and driving forces established by processes and operating conditions. In particular, water plays a key role as plasticizer, strongly influencing the state of amorphous materials via the glass transition and, thus, their mechanical properties. Therefore, it is important to improve the understanding about these complex phenomena and to develop useful prediction tools. For this aim, different modelling approaches have been applied in the food engineering field. The objective of this article is to provide a general (non-systematic) review of recent (2005-2021) and relevant works regarding the modelling and simulation of volume change and large deformation in various food products/processes. Empirical- and physics-based models are considered, as well as different driving forces for deformation, in order to identify common bottlenecks and challenges in food engineering applications.