Development of protein-Rich Sorghum-Based Expanded Snacks Using Extrusion Technology

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.

Sorghum in foods: Functionality and potential in innovative products

Sorghum grain is a staple food for about 500 million people in 30 countries in Africa and Asia. Despite this contribution to global food production, most of the world's sorghum grain, and nearly all in Western countries, is used as animal feed. A combination of the increasingly important ability of sorghum crops to resist heat and drought, the limited history of the use of sorghum in Western foods, and the excellent functional properties of sorghum grain in healthy diets, suggests a greater focus on the development of new sorghum-based foods. An understanding of the structural and functional properties of sorghum grain to develop processes for production of new sorghum-based foods is required. In this review, we discuss the potential of sorghum in new food products, including sorghum grain composition, the functional properties of sorghum in foods, processing of sorghum-based products, the digestibility of sorghum protein and starch compared to other grains, and the health benefits of sorghum. In the potential for sorghum as a major ingredient in new foods, we suggest that the gluten-free status of sorghum is of relatively minor importance compared to the functionality of the slowly digested starch and the health benefits of the phenolic compounds present.

A Cross-Sectional Audit of Sorghum in Selected Cereal Food Products in Australian Supermarkets

Sorghum (Sorghum bicolor (L.) Moench) may play a role in mechanisms that elicit favourable health effects. In Australia, sorghum is successfully grown, but it is not widely consumed, and its presence in common food products is unknown. This study examined the utilisation of sorghum in common food products, specifically breakfast cereals and snack bars, in a cross-sectional study of five supermarkets in New South Wales, over a 7-day period in February 2020. Details relating to ingredients, food format, brand, and product name were recorded. Sorghum was present in 6.1% (23/379) of breakfast cereals in a variety of formats, such as extruded shapes, flour, and puffed grain. In 8.7% of these, sorghum was listed as the first ingredient (greatest contribution by weight). Sorghum was utilised in 2% (6/298) of snack bars mainly as puffed sorghum and was listed in the fourth or subsequent position in the ingredient lists for all. 'Sorghum' did not appear in the name of any products. In conclusion, this baseline study indicates that sorghum is present in a small proportion of breakfast cereals and snack bars, highlighting the opportunity for greater investment in sorghum food innovation and marketing that would encourage consumer recognition and expand the product range.

Descriptive sensory analysis of instant porridge from stored wholegrain and decorticated pearl millet flour cooked, stabilized and improved by using a low-cost extruder

Pearl millet flour, particularly wholegrain flour, is highly susceptible to development of rancid aromas and flavors during storage. Grain decortication and extrusion cooking using a friction-heated single-screw extruder were investigated as potential flour stabilization processes. Raw and extruded wholegrain and decorticated grain pearl millet flours were stored at ambient (25°C) and elevated (40°C) temperatures for 6 months. A trained descriptive sensory panel developed a lexicon of 44 attributes to profile the aroma, flavor, and texture of porridges prepared from the flours. Grain decortication alone did not show an effect on the aroma and flavor profile of porridge. Extrusion cooking of both wholegrain and decorticated flours increased cereal-like aromas (branny, canned sweetcorn, sweet, and wheaty) and flavor (starchy), as well as stiffness and cohesiveness of the porridges. The porridges from the extruded pearl millet flours stored for up to 6 months at ambient and elevated temperatures did not show any indications of rancidity. In contrast, rancidity-associated aromas (chemical, painty, and soapy) and flavor (chemical) increased in porridges from the raw flours stored for 4 weeks and longer. These results indicate that grain decortication did not sufficiently reduce fat content to prevent oxidation, while extrusion cooking stabilized the pearl millet flours. In addition, intensified "cereal-like" aromas and flavors were probably due to Maillard reactions occurring during extrusion cooking. Resulting aroma compounds could have been immobilized in the extruded matrix and not released during flour storage. The application of extrusion cooking with a simple friction-heated single-screw extruder is a viable process for both precooking and extending the shelf life of pearl millet flours. PRACTICAL APPLICATION: This study demonstrates the potential of extrusion cooking to precook wholegrain pearl millet while preventing fat rancidity in wholegrain pearl millet flour, thereby improving the sensory quality and stability of pearl millet food products. The extensive sensory characterization of pearl millet porridge-type foods can serve as a guidance tool for development, improvement, and quality control of pearl millet foods. Furthermore, it establishes the efficacy of simple friction-heated, single-screw extruders for commercial manufacture of ready-to-eat wholegrain pearl millet food products by small and medium scale entrepreneurs.

Investigation on mild extrusion cooking for development of snacks using rice and chickpea flour blends

A study was conducted to optimize the mild extrusion cooking conditions for development of rice and chickpea based extrudates. The independent variables i.e. extrusion parameters (Screw speed, barrel temperature), feed moisture and proportions of rice flour and chickpea flour were varied using central composite rotatable design (CCRD), and their effects on system parameter- Specific mechanical energy (SME) and product characteristics i.e., water absorption index (WAI), water solubility index (WSI), bulk density (BD), expansion ratio (ER), breaking strength (BS), colour values (L*, a* and b*) and overall acceptability (OA) were studied. All the system and product responses were significantly affected by independent variables. Response surface and regression models were established to determine the responses as function of process variables. Models obtained were highly significant with high coefficient of determination (R² ≥ 0.889). The optimum mild extrusion conditions obtained by numerical optimization for development of snacks were 102 °C barrel temperature, 281 rpm screw speed, 18.3% feed moisture and rice to chickpea flour ratio as 90:10. Storage studies confirmed that the developed snacks can be stored better in laminated pouches than in high density polyethylene (HDPE) bags for a period of 6 months under ambient conditions.

Whole nuña bean (Phaseolus vulgaris L.) flour showed higher direct expansion during extrusion processing at relatively lower temperatures

Nuña bean, also known as "popping" bean, belongs to the group of common beans (Phaseolus vulgaris, L.). Originated in Andean mountains, nuña beans is an important food crop in several South American countries, including Bolivia, Ecuador, and Peru, where it is consumed primarily as a snack. Nuña beans are highly nutritious and have a distinctive nutty flavor, which makes them potentially desirable ingredients in food applications, such as extruded snacks. Thus, the goal of this study was to evaluate the performance of whole seed nuña bean flour during extrusion cooking. Expansion characteristics of whole nuña bean flour were investigated using a twin-screw extruder. Three levels of moisture contents of 15%, 18%, and 21% (wet basis), three barrel temperatures of 120, 140, and 160 °C, and three screw speeds of 150, 200, and 250 rpm were evaluated, with a die diameter of 3.15 mm. The expansion ratio (ER) ranged from 1.41 to 3.03, within the extrusion conditions studied. The moisture content and screw speed were found to have the most significant impact on the ER. Lower temperature and higher screw speed resulted in higher ER. The maximum ER of 3.03 was observed at a moisture content of 15%, a barrel temperature of 120 °C, and a screw speed of 250 rpm. Nuña bean flour exhibited good expansion properties at relatively low temperatures, which highlights its potential for use in extruded food applications such as nutritious snacks. PRACTICAL APPLICATION: There is increasing consumer demand for more nutritional snacks and cereals. Nuña bean flour exhibited potential for use in such nutritious products. This provides the industry with an alternative source of protein and fiber for inclusion in expanded food products.

Effect of the nixtamalization process on the protein bioaccessibility of white and red sorghum flours during in vitro gastrointestinal digestion

Protein bioaccessibility is a major concern in sorghum (Sorghum bicolor L. Moench) due to potential interactions with tannins affecting its nutritional value. Technological treatments such as boiling or alkaline cooking have been proposed to address this problem by reducing tannin-protein interactions. This research aimed to evaluate the impact of nixtamalization in the protein bioaccessibility from two sorghum varieties (red and white sorghum) during in vitro gastrointestinal digestion. Nixtamalization increased protein bioaccessibility in the non-digestible fraction (NDF) (5.26 and 26.31% for red and white sorghum, respectively). However, cooking showed a higher permeation speed of protein from red sorghum flours at the end of the intestinal incubation (9.42%). The SDS-PAGE profile of the digested fraction (DF) at 90 min of intestinal incubation indicated that, for red sorghum, cooking allows the formation of α and γ-kafirins while nixtamalization increase α-kafirin release. Principal Components Analysis (PCA) showed the association between nixtamalization and dissociation of δα kafirin complexes and increased protein content in the digestible fraction. In silico interactions indicated the highest biding energies for (+)-catechin and kafirin fractions (β-kafirin: -7.0 kcal/mol; γ-kafirin: -5.8 kcal/mol, and δ-kafirin: -6.8 kcal/mol), suggesting a minor influence of depolymerized proanthocyanidin fractions with sorghum proteins as a result of the nixtamalization process. In conclusion, nixtamalization increased the bioaccessibility of sorghum proteins, depolymerizing condensed tannins, and breaking protein-tannin complexes. Such technological process improves the nutrimental value of sorghum, supporting its inclusion in the human diet.

Tilapia-waste flour as a natural nutritional replacer for bread: A consumer perspective

Six bread formulations with different levels of tilapia-waste flour (BTF0%, BTF2.5%, BTF5%, BTF10%, BTF15%, and BTF20%) were analyzed for nutritional composition and sensory characterization. Tilapia-waste flour (TF) increased (P < 0.05) the lipid, protein and ash contents, and decreased (P < 0.05) the levels of carbohydrates and total dietary fiber. BTF0%, BTF2.5% and BTF5% received the highest (P < 0.05) scores for acceptance and preference. Despite this apparent consumer preference for low or no levels, TF can be added to bread at levels below 12.17% (P < 0.05) without triggering consumer rejection. TF changed (P < 0.05) the sensory characterization of bread because of a disagreeable flavor, aroma, and texture; however, airy appearance, sticky in the teeth and cream color did not influence the overall liking. TF at 5% enhanced the nutritional value while maintaining acceptable sensory scores for bread, constituting a potential strategy to satisfy consumer and industry requirements.

Relationships between morphometrical properties and the texture of an extrusion-expanded snack made from squid mantle (Dosidicus gigas)

The giant squid (Dosidicus gigas) is a species of commercial interest as a source of protein, and it can be developed into ready-to-eat food products, including expanded extrusion snacks (EES). EES are prepared primarily from starch; however, adding animal protein increases the nutritional contents. The objective of this study was to evaluate the effect of the protein-carbohydrate interactions on the physical and morphological characteristics of an EES made of squid mantle and potato-corn flour. The independent variable was the squid mantle content (40, 60, 80, and 100%) and two controls (0₁  = 100% potato, 0₂  = 100% corn). The expansion rate (ER) of the sample is significantly minor (p < .5) when the squid mantle content increases ER = 2.0, 1.8 1.4 to 40, 60, and 80%, respectively. In samples with more protein, crispness and crunchiness were reduced, whereas the hardness increased. Digital imaging analysis indicated that the interaction between protein and starch causes significant morphometric changes to the fractal dimension (2.665-2.739) and lacunarity (0.61-1.29). The results showed that it is possible to incorporate up to 60% squid mantle to prepare EES that possess texture and morphometric characteristics competitive in reported studies with snacks usually incorporating flours, corn, and wheat in the formulations.

PRACTICAL APPLICATIONS

The giant squid is a very attractive species because its meat has low caloric intake, high protein content, and is an important source of omega 3 fatty acids. Despite the desirable qualities of the squid meat its consumption is very low due to the low diffusion of the properties of its meat, acid, and ammoniacal flavor, rigid texture that requires prolonged cooking times and lack of alternatives of consumption. In Mexico, this type of squid is mainly destined for export as frozen mantle and products with little added value, which generates little economic benefit. Therefore, the results of this research may be of interest to the squid processing industry, which demands new forms of consumption of this marine species to increase their commercialization and added value.

Newly formulated, protein quality-enhanced, extruded sorghum-, cowpea-, corn-, soya-, sugar- and oil-containing fortified-blended foods lead to adequate vitamin A and iron outcomes and improved growth compared with non-extruded CSB+ in rats

Corn and soyabean micronutrient-fortified-blended foods (FBF) are commonly used for food aid. Sorghum and cowpeas have been suggested as alternative commodities because they are drought tolerant, can be grown in many localities, and are not genetically modified. Change in formulation of blends may improve protein quality, vitamin A and Fe availability of FBF. The primary objective of this study was to compare protein efficiency, Fe and vitamin A availability of newly formulated extruded sorghum-, cowpea-, soya- and corn-based FBF, along with a current, non-extruded United States Agency for International Development (USAID) corn and soya blend FBF (CSB+). A second objective was to compare protein efficiency of whey protein concentrate (WPC) and soya protein isolate (SPI) containing FBF to determine whether WPC inclusion improved outcomes. Eight groups of growing rats (n 10) consumed two white and one red sorghum–cowpea (WSC1 + WPC, WSC2 + WPC, RSC + WPC), white sorghum–soya (WSS + WPC) and corn–soya (CSB14 + WPC) extruded WPC-containing FBF, an extruded white sorghum–cowpea with SPI (WSC1 + SPI), non-extruded CSB+, and American Institute of Nutrition (AIN)-93G, a weanling rat diet, for 4 weeks. There were no significant differences in protein efficiency, Fe or vitamin A outcomes between WPC FBF groups. The CSB+ group consumed significantly less food, gained significantly less weight, and had significantly lower energy efficiency, protein efficiency and length, compared with all other groups. Compared with WSC1 + WPC, the WSC1 + SPI FBF group had significantly lower energy efficiency, protein efficiency and weight gain. These results suggest that a variety of commodities can be used in the formulation of FBF, and that newly formulated extruded FBF are of better nutritional quality than non-extruded CSB+.

Correlations between the physical properties and chemical bonds of extruded corn starch enriched with whey protein concentrate

The effects of extrusion temperature and whey protein concentration on the physical properties of corn starch were studied. Correlations between the physical properties of the extrudates and internal chemical bonds in proteins were studied using Pearson's statistical method.

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.