Effects of extrusion conditions on secondary extrusion variables and physical properties of fish, rice-based snacks

Reduction of antinutrients and off-flavour in kidney bean flour by acidic and alkaline reactive extrusion

The presence of antinutrients and undesirable flavours in kidney bean flour poses challenges to consumer acceptance. Although extrusion can mitigate antinutrients to some extent, its impact on reducing beany flavour in bean flour remains underexplored. This study investigated the effects of injecting acetic acid or sodium carbonate solutions at three concentration levels (0.05, 0.1, 0.15 mol/L), in conjunction with three temperature profiles (40/60/80/80/90, 40/60/80/90/110, 50/70/90/110/130 °C) and two feed moisture levels (25, 30 %), on the removal of antinutrients (condensed tannins, trypsin inhibitor activity, phytic acid, raffinose family oligosaccharides) and reduction of volatile compounds that contribute to beany flavour in whole kidney bean flour. The results showed that all concentrations of acetic acid and sodium carbonate solutions effectively reduced condensed tannins compared to water, especially at 130 °C extrusion temperature. Introducing acetic acid and sodium carbonate solutions at a concentration of 0.15 mol/L led to 72 and 90 % reduction of total raffinose family oligosaccharide content, respectively, in contrast to the 17 % reduction observed with water alone. The incorporation of sodium carbonate solution reduced the total volatile compounds by 45-58 % as compared with water (23-33 %) and acetic acid (11-27 %). This reduction was primarily due to the reduction of aldehydes, alcohols, and aromatic hydrocarbons. These results indicate that injecting sodium carbonate solution during extrusion can effectively reduce antinutrients and beany flavour compounds in kidney bean flour.

Mild Approach for the Formulation of Chestnut Flour-Enriched Snacks: Influence of Processing Parameters on the Preservation of Bioactive Compounds of Raw Materials

Third-generation snacks were developed from a triad of flours made up of chestnut, spelt, and chickpea flour. Optimal snack formulations and processing parameters have been established to ensure acceptable workability of the raw dough while protecting the bioactive components of the raw materials. The parameters examined were mixing time, speed, and temperature. The properties of the snack were evaluated by analyzing the expansion ratio, hardness, moisture content, and phenolic and volatile compounds. The optimal mixing conditions that ensure maximum expansion were a temperature of 30 °C, a speed of 30 rpm, and a time of 6 min. The results showed that the proper percentage of water and sodium bicarbonate was 35% and 2%, respectively, and that the developed snacks had an alveolar and homogeneous structure. The proposed approach brings several advantages, including the preservation of bioactive compounds during the production process. Furthermore, the mild operating conditions prevented the development of unwanted or unpleasant compounds, as confirmed by the analysis of volatile compounds. Therefore, this study opens new perspectives in the food industry, satisfying the growing demand for functional products and healthy snacks.

Technological and prebiotic aspects of young bamboo culm flour (Dendrocalamus latiflorus) combined with rice flour to produce healthy extruded products

Young bamboo culm flour (YBCF) has proved to be a healthy and sustainable ingredient, due to its high fiber content and high yield of bamboo crops. The present study evaluated the effects of YBCF from Dendrocalamus latiflorus on the physicochemical, technological properties and prebiotic activity of rice-based extrudates aiming to expand its application. The extrudates were produced in a twin-screw extruder with different RF:YBCF concentrations (100:0; 95:5, 90:10, and 85:15 %). During the process, the specific mechanical energy increased as YBCF content increased because of the high shear favored by YBCF particles. With increasing RF replacement by YBCF, the extruded products presented a significant (p < 0.05, by the Scott-Knott test) increase in hardness (57.37 to 82.01 N) and water solubility index (12.80 to 34.10 %), as well as a decrease in color luminosity (L*=85.49 to 82.83), expansion index (2.68 to 1.99), and pasting properties. In addition, all extrudate samples presented bifidogenic activity. Therefore, YBCF exhibited attractive technological properties and can be used as an ingredient in the production of healthy and sustainable extruded products.

Extrusion parameters and physical transformations of an extrudate for fish: Effect of the addition of hydrolyzed protein flour from by-products of Oncorhynchus mykiss

Introduction

The food industries play a fundamental role in feeding for the functions of animal metabolism. Fish feed extrusion cooking includes process-independent factors such as temperature (°C), screw speed (RPM), throughput, feed, and moisture content that influence the final product's nutritional value and physical properties. The evidence suggests that the application of hydrolyzed protein flour (HPH) is a crucial step for the techno-functional properties of the product. Therefore, this work aimed to study the effect of hydrolyzed protein meal from silage of trout (Oncorhynchus mykiss) on the parameters of the extrusion system and their physical transformations.

Methods

In this study, the influence of hydrolyzed protein meals ranges between 10 and 30% as a substitute for fish meals. The physical properties of the extrudate were monitored, evaluating the hardness, durability, buoyancy, expansion index, and apparent density.

Results

Consistent with this, parameters such as feed composition, screw speed, moisture content, and extrusion process affected the composition and properties of the final product.

Discussion

The physical properties indicated that the hydrolyzed protein flour presented cohesiveness and decreased the mean retention time in the extruder barrel and the specific mechanical energy (SME). Hydrolyzed protein flour during the extrusion process produces pellets with high durability and low hardness due to the high porosity presented, which allows for obtaining nutritional characteristics in the extruded product.

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 thermal energy on extrusion characteristics, digestibility and palatability of a dry pet food for cats

The influence of specific thermal energy (STE) applications on extruder preconditioner was evaluated in a dry food for cats. In the first study, six STE applications were tested with mass temperatures of 45°C, 55°C, 65°C, 75°C, 85°C and 95°C. The extrusion parameters, starch gelatinization and kibble formation were evaluated. Diets were given to cats to evaluate digestibility, faecal characteristics and palatability. In the second experiment, three treatments were compared: low STE-a preconditioner temperature of 45°C (_L STE); high STE-a preconditioner temperature of 95°C (_H STE); high STE (preconditioner temperature of 95°C) combined with an increase in the mass flow rate to obtain a motor amperage similar to that of the _L STE (_H STE_flow ). Data were analysed by polynomial contrasts (Experiment 1) or Tukey's test (Experiment 2; p < 0.05). An increase in STE reduced motor amperage, mass pressure and specific mechanical energy (SME) implementation (p < 0.001) and increased total specific energy (TSE) and mass temperature (p < 0.01). The increase in STE induced greater kibble expansion and starch gelatinization (p < 0.001). No changes in apparent nutrient digestibility or faeces characteristics were observed (p > 0.05). Lower STE and starch gelatinization induced higher butyrate and total volatile fatty acid (VFA) contents in faeces (p < 0.01). Cats showed greatest preference for the formulation with the highest STE (p < 0.01). In the second experiment, when the motor amperage was increased in the _H STE_flow treatment to a value similar to that of the _L STE, the mass flow rate increased 40%, and the electric energy consumption remained unchanged (p < 0.001), with gains observed for efficiency and cost. In conclusion, STE application is important for sufficient TSE implementation, enhancing kibble expansion, starch gelatinization, cat preferences for food, extruder productivity and reducing SME application. Foods with lower starch gelatinization lead to increased VFA in faeces, with possible implications for gut health.

Considerations for improvising fortified extruded rice products

Micronutrient fortification of rice by extrusion is an effective strategy to enhance micronutrient levels within rice-consuming individuals. The success of extrusion-based fortification is associated with micronutrient retention, enhanced bioavailability, low postprocessing losses, prolonged storage stability, and minimal sensory changes. The success of an optimally fortified product is primarily reliant upon the compositional considerations, but many attributes of extrudates can be indebted to the processing parameters too. Hence, an exhaustive investigation of this technology has been taken-up here, emphasizing on the compositional parameters in association with process parameters, which influence the final quality attributes like nutrient stability, bioavailability, and sensory properties. Based on these attributes of the end product, a collected data have been presented here to bring out the optimal compositional requirements. These together with cooking processes, extrusion process parameters, and storage conditions will enable formulate a product with enhanced sensory acceptance, better retention during cooking and storage, improved texture, and acceptable color. This review will thus help to optimize a need-based product, its quality, and enhance benefits of fortified extruded rice products.

Pea starch exhibits good expansion characteristics under relatively lower temperatures during extrusion cooking

Extrusion processing characteristics of pea starch were studied as impacted by various extrusion cooking processing variables, including, moisture content (15%, 17.5%, and 20% w.b.), temperature (120, 135, and 150 °C), and screw speed (150, 200, and 250 rpm), in a co-rotating twin-screw extruder. Physicochemical properties such as radial expansion ratio (ER), unit density (UD), water absorption index (WAI), and water solubility index (WSI) were measured. ER of the extrudates ranged between 2.52 and 3.63. These values of ER were significantly high, although relatively lower compared to the highest values reported in the literature for corn and rice extrudates. The UD values for all the extrudates ranged from 0.12 to 0.35 g/cm3 , WAI, and WSI values ranged from 10.98 to 12.10 g/g and from 0.12% to 7.73%, respectively. Both screw speed and moisture content had significant impacts on the ER (P < 0.01). The highest ER was observed for the extrusion cooking conditions of the lowest moisture content level (15%), lowest barrel temperature (120 °C), and lowest screw speed (150 rpm). The cross-sectional microstructure of the extrudates showed that the samples with a high ER had thick and elongated pores. The results of this study indicate that pea starch is a viable ingredient for making puffed extruded products. PRACTICAL APPLICATION: The food industry can utilize the information generated from this study in the development of extruded expanded food products with pea starch. The specific information related to process conditions can assist the food industry in determining the ideal conditions for extrusion cooking in the production.

Extruded whole buckwheat noodles: effects of processing variables on the degree of starch gelatinization, changes of nutritional components, cooking characteristics and in vitro starch digestibility

The effects of processing variables on the degree of gelatinization (DG), changes of nutritional components, cooking characteristics and in vitro starch digestibility of extruded whole buckwheat noodles were investigated.

Development of functional extruded snacks by utilizing paste shrimp (Acetes spp.): process optimization and quality evaluation

BACKGROUND

Functional extruded snacks were prepared using paste shrimp powder (Acetes spp.), which is rich in protein. The process variables required for the preparation of extruded snacks was optimized using response surface methodology. Extrusion temperature (130-144 °C), level of Acetes powder (100-200 g kg^-1 ) and feed moisture (140-200 g kg^-1 ) were selected as design variables, and expansion ratio, porosity, hardness, crispness and thiobarbituric acid reactive substance value were taken as the response variables.

RESULTS

Extrusion temperature significantly influenced all the response variables, while Acetes inclusion influenced all variables except porosity. Feed moisture content showed a significant quadratic effect on all responses and an interactive effect on expansion ratio and hardness. Shrimp powder incorporation increased the protein and mineral content of the final product. The extruded snack made with the combination of extrusion temperature 144.59 °C, feed moisture 178.5 g kg^-1 and Acetes inclusion level 146.7 g kg^-1 was found to be the best one based on sensory evaluation.

CONCLUSION

The study suggests that use of Acetes species for the development of extruded snacks will serve as a means of utilization of Acetes as well as being a rich source of proteins for human consumption, which would otherwise remain unexploited as a by-catch. © 2017 Society of Chemical Industry.

Filler functionality in edible solid foams

We review the functionality of particulate ingredients in edible brittle foams, such as expanded starchy snacks. In food science and industry there is not a complete awareness of the full functionality of these filler ingredients, which can be fibers, proteins, starch granules and whole grains. But, we show that much can be learned about that from the field of synthetic polymeric foams with (nano)fillers. For edible brittle foams the enhancement of mechanical strength by filler ingredients is less relevant compared to the additional functionalities such as 1) the promotion of bubble nucleation and 2) cell opening-which are much more relevant for the snack texture. The survey of particulate ingredients added to snack formulations shows that they cannot be viewed as inert fillers, because of their strong hygroscopic properties. Hence, these fillers will compete with starch for water, and that will modify the glass transition and boiling point, which are important factors for snack expansion. Filler properties can be modified via extrusion, but it is better if that processing step is decoupled from the subsequent processing steps as mixing and expansion. Several filler ingredients are also added because of their nutritional value, but can have adverse effect on snack expansion. These adverse effects can be reduced if the increase of nutritional value is decoupled from other filler functionality via compartmentalization using micropellets.

Effect of extrusion cooking on bioactive compounds in encapsulated red cactus pear powder

Red cactus pear has significant antioxidant activity and potential as a colorant in food, due to the presence of betalains. However, the betalains are highly thermolabile, and their application in thermal process, as extrusion cooking, should be evaluated. The aim of this study was to evaluate the effect of extrusion conditions on the chemical components of red cactus pear encapsulated powder. Cornstarch and encapsulated powder (2.5% w/w) were mixed and processed by extrusion at different barrel temperatures (80, 100, 120, 140 °C) and screw speeds (225, 275, 325 rpm) using a twin-screw extruder. Mean residence time (trm), color (L*, a*, b*), antioxidant activity, total polyphenol, betacyanin, and betaxanthin contents were determined on extrudates, and pigment degradation reaction rate constants (k) and activation energies (Ea) were calculated. Increases in barrel temperature and screw speed decreased the trm, and this was associated with better retentions of antioxidant activity, total polyphenol, betalain contents. The betacyanins k values ranged the -0.0188 to -0.0206/s and for betaxanthins ranged of -0.0122 to -0.0167/s, while Ea values were 1.5888 to 6.1815 kJ/mol, respectively. The bioactive compounds retention suggests that encapsulated powder can be used as pigments and to provide antioxidant properties to extruded products.

Response Surface Analysis for Preparation of Modified Flours using Twin Screw Extrusion Cooking

Rice flour, wheat flour and flour in combination (rice:wheat::50:50) were used to prepare modified flour using co-rotating twin screw extruder. The effects of barrel temperature, feed moisture and screw speed on product responses (specific mechanical energy[SME], expansion ratio and bulk density) were studied using response surface methodology. Extrusion variables were barrel temperature (125, 150 and 175°C), moisture content (14, 16 and 18%) and screw speed (300, 400 and 500 rpm). Expansion ratio was directly affected by barrel temperature, whereas increase in temperature decreased SME and bulk density. Feed moisture had positive effect on bulk density only, i.e. it increased with increase in moisture. Increase in screw speed was directly related to SME and expansion ratio. The higher R2 values showed that the model developed for the response variables appeared adequate for predictive purposes.

Studying the effects of nucleating agents on texture modification of puffed corn-fish snack

To improve textural attributes of puffed corn-fish snack, the effects of 1%, 1.5%, and 2% of calcium carbonate, magnesium silicate (talc), sodium bicarbonate as well as 5% and 10% of wheat bran (as the nucleating materials) on textural attributes were studied. Sensory evaluation, bulk density, expansion ratio, maximum force, and count peaks were measured using the Kramer test. The results showed that all of the additives except bran significantly enhanced the texture. Among them, talc at 0.5% was the best to enhance the density and expansion ratio. Effects of using 0.5% talc on puffed corn-fish snack microstructure were studied using scanning electron microscopy. The average cell diameter of 109 ± 48 μm and cell numbers per square centimeter of 67.4 for talc-treated products were obtained, while for nontalc-treated extrudates, average cell diameter of 798 ± 361 μm and cell numbers per square centimeter of 13.9 were found. Incorporation of 0.5% w/w of magnesium silicate reduced (7-fold) the average cell diameter while increased (4-fold) the cell number.

Development and evaluation of garlic incorporated ready-to-eat extruded snacks

The present study was carried out to develop and evaluate ready to eat extruded snacks incorporated with garlic powder at various levels (5 %, 10 %, 15 %, 20 %). The organoleptic evaluation was conducted for the developed products and the well accepted products were selected for further studies like physical properties and shelf life (stored at room temperature for 2 months). The organoleptic evaluation of the developed snacks revealed that 15 % and 20 % garlic incorporated snacks were not acceptable due to strong garlic flavor, therefore T1 (control), T2 (5 % garlic) and T3 ( 10 % garlic) were selected for further studies. The physical properties showed significant changes with incorporation of garlic powder at 0 %-10 % level. There was an increase in mass flow rate, tap density and bulk density but decrease in the water holding capacity, oil absorption capacity and expansion ratio. The water soluble index and moisture retention of the products showed the same values for all the three selected treatments. The products were packed by ordinary, nitrogen and vacuum packing and stored for 2 months. It was found that there was an increase in moisture content and microbial load, however the increase was within limits. The increase in the moisture content was low in nitrogen packed products where as the microbial load decreased with increase in the percentage of garlic incorporation. The nitrogen and vacuum packed products showed less microbial load than the ordinary packed products. Garlic powder can be incorporated at 5 and 10 % levels in ready-to-eat extruded snacks with well acceptability and can be stored for a period of 2 months with nitrogen packing as an effective packaging.

Quality characteristics and consumer acceptance of a high fish protein puffed corn-fish snack

Corn snack fortified with 7% fish protein powder made from saithe (Pollachius Virens) surimi was selected by expert panel from industry for consumer studies in Iran and Iceland. They hedonically screened products with 3%, 5%, 7% and 9% fish protein powder. Snack containing 9% fish protein powder (FP) had significantly lower liking for odour, texture, flavour, and overall acceptability than the other three prototypes. Snacks fortified with 3%, 5%, and 7% FP had similar sensory attributes. Therefore, snack with the highest level of FP (7%) was selected for acceptance tests. It was seasoned with cheese powder, vegetable oil, salt, and colorant. The amount of protein, moisture, fat, ash and salt in fortified corn snack (FCS) was 12%, 2%, 31%, 3%, and 2% respectively. Consumers' acceptance was studied using a central location test method. Consumers were 6-16 years old children in two communities (Iceland and Iran). They liked FCS but Iranian children favoured it more than Icelandic children. Majority of parents of the participants expressed their willingness to choose this product when buying snacks.