Development of whole grain wheat flour extruded cereal and process impacts on color, expansion, and dry and bowl-life texture

Impact of moisture content on microstructural, thermal, and techno-functional characteristics of extruded whole-grain-based breakfast cereal enriched with Indian horse chestnut flour

The use of non-conventional seed flour is of interest in obtaining healthy breakfast cereals. The research aimed to study the physico-functional, bioactive, microstructure, and thermal characteristics of breakfast cereals using scanning electron microscopy, X-ray diffractometry, and differential scanning calorimeter. The increase in feed moisture content (16 %) enhanced the bulk density (5.24 g/mL), water absorption index (7.76 g/g), total phenolic content (9.03 mg GAE/g), and antioxidant activity (30.36 %) having desirable expansion rate (2.84 mm), water solubility index (48 %), and color attributes. The microstructure showed dense inner structures with closed air cells in extruded flours. Extrusion treatment rearranged the crystalline structure from A-type to V-type by disrupting the granular structure of starch, reducing its crystallinity, and promoting the formation of an amylose-lipid complex network. Increasing conditioning moisture enhanced the degree of gelatinization (%), peak gelatinization temperature (Tp), and starch crystallinity (%) and reduced the gelatinization enthalpy (ΔHG) and gelatinization temperature ranges. The results reported in this study will help industries to develop innovative and novel food products containing functional ingredients.

Effect of wheat dextrin on corn flour extrusion characteristics

Wheat dextrin is a modified wheat starch, classified as water-soluble. This study investigated the effect of wheat dextrin as an ingredient in corn flour blends on extrusion characteristics. Blends were prepared at 0, 10 and 20 % fibre content. DOE was used to design experiments and investigate the effects of variables selected to be studied. Feed moisture content was set at 18-25 %, temperature at 110-150 °C and specific feeding load at 0.100-0.150kg/rev. Moisture content, water absorption and solubility indices, color, sectional expansion index, density, hardness, crispiness (work (Wc) and number of spatial ruptures (Nsr)) and specific mechanical energy were evaluated. A regression model was established using response surface methodology, and processing conditions for optimal quality were generated (e.g., WSI: 96.9 %, SME: 96.9 %, final MC: 93.9 %). Wheat dextrin solubility characteristics for moisture content, WAI and WSI were inconclusive, showing a high tendency to insoluble behavior. For expansion, lightness and SME characteristics depended on processing conditions, especially temperature. Crispness was highest at low MC (18.87 %) x high fiber content (20 %) (e.g., Nsr: 1.2-1.5/mm), whereas values were the lowest at high MC (25.70 %) x low fiber content (0 %) (e.g., Nsr: 0.5-0.7/mm). Optimal conditions were set at 12 % fiber content, 19 % feed moisture content, 130 °C and a specific feeding load of 0.146 kg/rev. This study showed that it is impossible to classify wheat dextrin as acting strictly according to soluble fiber characteristics based on extrudate characteristics.

New Breakfast Cereal Developed with Sprouted Whole Ryegrass Flour: Evaluation of Technological and Nutritional Parameters

Ryegrass is one such cereal that has been underutilized in human nutrition despite its high nutritional and functional value due to the presence of phytochemicals and dietary fibers. Exploiting ryegrass for human consumption is an exciting option, especially for countries that do not produce wheat, as it is easily adaptable and overgrows, making it economically viable. This study evaluated the nutritional content of γ-aminobutyric acid and bioactive compounds (total soluble phenolic compounds) and the physicochemical and technological properties of partially substituting maize flour (MF) with sprouted whole ryegrass flour (SR) in developing extrusion-cooked breakfast cereals. A completely randomized design with substitutions ranging from 0 to 20% of MF with SR was employed as the experimental strategy (p < 0.05). Partial incorporation of SR increased the content of γ-aminobutyric acid and total soluble phenolic compounds. Using sprouted grains can adversely affect the technological quality of extruded foods, mainly due to the activation of the amylolytic enzymes. Still, ryegrass, with its high dietary fiber and low lipid content, mitigates these negative effects. Consequently, breakfast cereals containing 4 and 8% SR exhibited better physicochemical properties when compared to SR12, SR16, SR20, and USR10, presenting reduced hardness and increased crispness, and were similar to SR0. These results are promising for ryegrass and suggest that combining the age-old sprouting process with extrusion can enhance the nutritional quality and bioactive compound content of cereal-based breakfast products while maintaining some technological parameters, especially crispiness, expansion index, water solubility index, and firmness, which are considered satisfactory.

Sustainable production of naturally colored extruded breakfast cereals from blends of broken rice and vegetable flours

There is a growing demand for practical and healthy food products. Obtaining naturally colored breakfast cereals with the incorporation of functional ingredients is a promising alternative for consumers that are looking for healthiness. This study aimed to evaluate the feasibility of using vegetable flours, rich in pigments, to obtain naturally colored breakfast cereals through thermoplastic extrusion. Vegetables considered "unsuitable for the retail market", classified as "type B", were used to prepare different flours from carrot (CF), spinach (SF) and beetroot (BF). Extrudates were produced from a mixture of 90% broken rice (BR) and 10% vegetable flour (CF, SF or BF). Besides giving the extrudates a natural color, the use of vegetable flours also provided nutritional and functional enrichment due to increased mineral, protein, lipid, fiber and phenolic compound contents, and greater antioxidant capacity. However, some of these components, such as fibers, affect extrudate physical structure and technological characteristics, evidenced by reduced expansion, hardness, paste viscosity and greater interaction with water present in milk under consumption conditions. In general, the evaluated flours proved to be an alternative for imparting a natural color to extruded breakfast cereals, in addition to positively contributing to their nutritional and functional value.

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.

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.

Andean purple maize to produce extruded breakfast cereals: impact on techno-functional properties and sensory acceptance

BACKGROUND

Andean purple maize (APM) is an ancient crop widely used as a natural coloring in traditional Peruvian cuisine. However, it has been little explored within the food industry. The present study assessed how APM impacts on techno-functional properties and sensory acceptance of breakfast cereals. Extruded samples formulated with 100, 75, 50, and 25% APM, and complemented with yellow corn grits (YCG), were analyzed for their techno-functional and sensory properties.

RESULTS

Increases in bulk density, as well as reduction in the expantion and porosity were observated for extrudates containing ≥ 50% APM, accompanied by an increase in purple color intensity. Increase in milk absorption index, reduction in milk solubility index and decrease in cereal hardness with increase in APM were also observed. Despite this, APM extented the cereal bowl-life. High sensory scores of overall liking (6) and color (7) were obtained for extruded formulations containing ≥ 50% APM and low values for extrudates with 25% APM. Aroma, flavor, and texture scores did not present significant differences.

CONCLUSION

APM is an ingredient with the potential to be used to produce breakfast cereals since it improves their techno-functional characteristics and sensory acceptance, at the same time, it leads to the production of healthy, nutritious, and sustainable food. © 2022 Society of Chemical Industry.

Physical, Chemical and Functional Attributes of Neera Honey Infused Extrudates

Owing to the demand for the consumption of healthy extrudates, this study explored the infusion of neera (coconut inflorescence sap) honey in rice flour, corn flour and coconut milk residue blend-based extrudates. Neera honey, the concentrated coconut inflorescence sap, has numerous nutrients and a natural source of essential vitamins. Hence, the potential of neera honey as a biofortifying compound for the production of healthy extrudates was investigated. The rice and corn based extrudates supplemented with different concentration of neera honey have been prepared until the mix reaches 16 and 20% (w.b.) of feed moisture. Effect of addition of neera honey on the physical properties (expansion ratio, bulk density, specific length), functional properties (water absorption, water solubility, oil absorption), biochemical properties (total carbohydrates, total sugar, reducing sugar, phenolics, flavonoids, antioxidants), color parameters(L*, a*, b*), proximate compositions (moisture content, ash, protein, fat) and mineral profile of extrudates were recorded. Results suggest that addition of neera honey had a significant (p ˂ 0.05) impact on all the physico-chemical parameters evaluated. Incorporation of neera honey (feed moisture -20%) resulted in extrudates with less expansion, high bulk density and specific length, having high sugar, protein, phenolics, vitamin C and antioxidant activity. The combination of 60% rice flour + 25% corn flour +15% coconut milk residue samples infused with neera honey upto 16% feed moisture was found suitable for the preparation of nutritious extrudates based on functional characterization and minerals evaluation.

Novel infrared puffing: Effect on physicochemical attributes of puffed rice ( Oryza sativa L.)

The effect of novel infrared (IR) puffing and various IR powers (350, 450, and 550 Watts [W]) at various distances (10, 20, and 30 cm) on physicochemical characteristics of puffed rice (puffing properties, color, total phenolic content [TPC], antioxidant activity, peroxide value, and morphology) was investigated. By reducing the distance and increasing the IR power, the volume puffing was significantly increased (p < .05), and bulk density was significantly decreased (p < .05) but there was no significant difference in the length/breadth ratio. The IR puffing effect on color, the TPC, antioxidant activity, and food compounds' analysis through Fourier transform infrared (FTIR) spectra were significant (p < .05) during IR puffing. The scanning electron microscopy (SEM) images showed that by increasing the IR power and decreasing the sample distance from the IR source, the size of protrusions was increased (the volume of the protrusions). The maximum increase in the protrusions size was observed in 10 cm distance and 550 W power of IR. This is the first report on the IR puffing of rice and according to the results, the IR puffing technology has a high efficiency at the rice puffing.

Nutritional Function and Flavor Evaluation of a New Soybean Beverage Based on Naematelia aurantialba Fermentation

The soy beverage is a healthy product rich in plant protein; however, its unpleasant flavor affects consumer acceptance. The aim of this study was to determine the feasibility of using Naematelia aurantialba as a strain for the preparation of fermented soybean beverages (FSB). Increases in Zeta potential, particle size, and viscosity make soy beverages more stable. We found that nutrient composition was increased by fermenting N. aurantialba, and the antioxidant activity of soybean beverages significantly increased after 5 days of fermentation. By reducing the content of beany substances such as hexanal and increasing the content of 1-octen-3-ol, the aroma of soybean beverages fermented by N. aurantialba changed from “beany, green, and fatty” to “mushroom and aromatic”. The resulting FSB had reduced bitterness but considerably increased sourness while maintaining the fresh and sweet taste of unfermented soybean beverages (UFSB). This study not only provides a theoretical basis for the market promotion of FSB but also provides a reference for basidiomycetes-fermented beverages.

Effect of Die Configuration on the Physico-Chemical Properties, Anti-Nutritional Compounds, and Sensory Features of Legume-Based Extruded Snacks

Legumes are not valued by all consumers, mostly due to the prolonged soaking and cooking process they require. This problem could be solved by preparing legume-based ready-to-eat snacks. In this study, the effect of two different dies (circular and star-shaped, with cross-sections of 19.6 and 35.9 mm2, respectively) on the physico-chemical properties, anti-nutritional compounds, and sensory features of extruded breakfast snacks was determined. Extruded products were obtained from 100% legume flours of red lentil, faba bean, brown pea, and common bean. The extrusion-cooking conditions were 2.5 g/s feed rate; 160 ± 1 °C die temperature; 16 ± 1 g/100 g feed moisture, and 230 rpm screw speed. Star-shaped extrudates showed a lower expansion ratio, degree of starch gelatinization, and water solubility index, as well as higher bulk density, hardness, crunchiness, and lightness (L*) values. The oligosaccharides showed non univocal variations by changing the die, whereas phytates did not vary at all. The extrudates from lentil flour (richer in fiber) were the least preferred by sensory panelists, due to their hard texture. However, the spherical extrudates were preferred over the star-shaped product. These results emphasize the possibility of improving the physico-chemical and sensory properties of legume extrudates by selecting a proper die.

Release of characteristic phenolics of quinoa based on extrusion technique

Quinoa is rich in phenolics which are benefit for human health for their outstanding antioxidant capacity, anti-inflammatory property and special biological functions. However, most of phenolics existed as bound form that with low bioavailability in quinoa. In this study, extrusion technique was applied for the release of bound phenolics in red quinoa (RQ), and effects of extruded temperature (120 °C, 140 °C, 160 °C and 180 °C) on the release of characteristic phenolics of RQ was investigated as well. Phenolics both presented as free and bound forms were identified in RQ and extruded quinoa samples, and result showed rutin, ferulic acid and vanillic acid were most common. The content of bound phenolics in RQ was 155.52 mg/kg, however, in extruded red quinoa (ERQ) was 77.25 mg/kg (ERQ-140 °C)-84.08 mg/kg (ERQ-120 °C). In corresponding, free phenolics in RQ was 22.15 mg/kg, while in ERQ was 41.04 mg/kg (ERQ-140 °C)-47.25 mg/kg (ERQ-160 °C). In conclusion, extrusion was excellent for the release of bound phenolics in quinoas and the best extruded temperature was 160 °C. Extrusion technique was potential in the processing of quinoa.

Physical and technofunctional properties of yellow pea flour and bread crumb mixtures processed with low moisture extrusion cooking

The potential utilization of yellow pea flour and bread crumb blends was investigated to generate nutritionally-dense extruded products with superior physical and/or technofunctional properties. Yellow pea flour mixed with bread crumb at different ratios were processed using low-moisture twin-screw extrusion cooking conditions to examine the effect of blending ratios and feed moisture contents on physical (that is, radial expansion index, extrudate density, microstructure, texture, and color) and technofunctional (that is, emulsifying capacity, emulsifying stability, water solubility [WS], water binding capacity [WBC], oil binding capacity [OBC], and pasting) properties of the final products. Compared to the two feed materials alone, samples produced with yellow pea flour and bread crumb blends showed lower hardness and higher crispiness. Moisture content (12% to 18%) was found to significantly affect physical and technofunctional properties. With an increase in feed moisture content from 12% to 18%, the WBC of the extrudates increased while the WS decreased. Extrudates produced with higher feed moisture content, and higher yellow pea flour content had higher setback viscosity. Among all formulas and feed moisture contents studied, extrudates produced with 50% yellow pea flour and 50% bread crumb at 12% feed moisture content had the highest radial expansion and bigger cells with thinner cell walls. This study has shown that incorporation of yellow pea flour and bread crumb in extrusion cooking process could be used to develop nutritionally-dense foods with improved physical and technofunctional properties.

Production of innovative gluten-free breakfast cereals based on red and black rice by extrusion processing technology

The transformation of black and red, broken or not, whole rice grains, into breakfast cereals is an interesting way to add value to these snacks for some reasons. Firstly, broken kernels hardly achieve a high market value; whole rice is healthy not only for their nutrient contents but also for their phytochemical profile, rich in phenolic compounds; breakfast cereals from pigmented rice are colored by themselves, and any additional colorant is unneeded; finally, rice is naturally gluten-free and suitable for those with conditions like celiac disease or gluten sensitivity. The objective of this study was to optimize some extrusion parameters that account for the physicochemical properties of extrudates by using response surface methodology. Feed moisture between 15 and 21% and the 4th barrel zone temperature between 110 and 160 °C were the independent variables. Specific features such as color, texture, water solubility and absorption, cold viscosity, expansion, specific volume, and compression force were evaluated. The trials have shown that moisture had a higher impact on the extrusion process than temperature. Less expanded, denser, harder, and darker products were obtained at higher moisture levels. The optimum points were defined at 15.5% and 16.0% of feed moisture and 159 °C and 150 °C of temperature for black and red rice extrudates, respectively. These conditions resulted in cereal breakfast balls with optimal water solubility, volume, texture, and good color. Additionally, cold viscosities and a low compression led to products with a potential high approval by consumers.