Multiscale analysis of structure development in expanded starch snacks

Analytical and numerical solutions of pore formation in elastic food materials during dehydration

In this paper, we describe a model for pore formation in food materials during drying. As a proxy for fruits and vegetables, we take a spherical hydrogel, with a stiff elastic skin, and a central cavity filled with air and water vapour. The model describes moisture transport coupled to large deformation mechanics. Both stress and chemical potential are derived from a free energy functional, following the framework developed by Suo and coworkers. We have compared Finite Volume and Finite Element implementations and analytical solutions with each other, and we show that they render similar solutions. The Finite Element solver has a larger range of numerical stability than the Finite Volume solver, and the analytical solution also has a limited range of validity. Since the Finite Element solver operates using the mathematically intricate weak form, we introduce the method in a tutorial manner for food scientists. Subsequently, we have explored the physics of the pore formation problem further with the Finite Element solver. We show that the presence of an elastic skin is a prerequisite for the growth of the central cavity. The elastic skin must have an elastic modulus of at least 10 times that of the hydrogel. An initial pore with 10% of the size of the gel can grow to 5 times its initial size. Such an increase in porosity has been reported in the literature on drying of vegetables, if a dense hard skin is formed, known as case hardening. We discuss that models as presented in this paper, where moisture transport is strongly coupled to large deformation mechanics, are required if one wants to describe pore/structure formation during drying and intensive heating (as baking and frying) of food materials from first principles.

Causal factors concerning the texture of French fries manufactured at industrial scale

In this paper, we review the physical/chemical phenomena, contributing to the final texture of French fries, as occurs in the whole industrial production chain of frozen par-fried fries. Our discussion is organized following a multiscale hierarchy of these causal factors, where we distinguish the molecular, cellular, microstructural, and product levels. Using the same multiscale framework, we also discuss currently available theoretical knowledge, and experimental methods probing the relevant physical/chemical phenomena. We have identified knowledge gaps, and experimental methods are evaluated in terms of the effort and value of their results. With our overviews, we hope to give promising research directions such to arrive at a multiscale model, encompassing all causal factors relevant to the final texture. This multiscale model is the ultimate tool to evaluate process innovations for effects on final textural quality, which can be balanced against the impacts on sustainability and economics.

Dust formation in French fries

In this study we report on the analysis of dust formation, a quality problem arising in the industrial processing of par-fried, frozen french fries. This dust constitutes fractured pieces broken off the crust during finish frying. We claim that this dust problem has many similarities with flaking arising during the final-baking of par-baked french baguettes, i.e. the two problems are governed by the same physical principles. Inspired by the hypotheses behind flaking, we have made an experimental design, where we have perturbed the operating conditions of an industrial processing line of french fries. The measured dust during finish frying is correlated with the physical properties of the crust, measured in the different unit operations of the industrial processing line, and the operating conditions. We have shown that dust is non-linearly correlated to 1) the moisture content of the crust as influenced by drying and par-frying, and 2) the freezing rate in the industrial tunnel freezer. Remarkably, the amount of dust decrease with the increase of frozen storage time, which we have explained via viscoelastic relaxation of locked-in stress - mediated by moisture migrating from core to crust. This decay is shown to be independent of pretreatments, which only determines its starting value. With the given relations industry can in principle control the dust problem, but these measures have to be weighed against their effects on other objectives of the industry.

Thermodynamic description of the chemical leavening in biscuits

In this paper we describe the chemical reactions of leavening agents in baking biscuits on a sound thermodynamic basis. The model is part in a sequel targetted at physical understanding of biscuit baking with the purpose of reformulation of biscuits with respect to sucrose and sodium levels. The chemical leavening gases, CO2 and NH3, originate from the dissociation of sodium and ammonium bicarbonate. Next to water vapour, these produced gases create gas bubbles in the biscuit dough. The concentrations of the leavening agents and added salt lead to high ionic strength. Consequently, the activities of ions participating in the leavening reaction deviate strongly from ideality. The non-idealities are described using the Pitzer equations. The values of many parameters of the Pitzer model and equilibrium constants are obtained from the strong developed field of CO2 sequestering in ammonia solutions. The model describing the chemical reactions is coupled to a cell model describing the expansion of gas bubbles. Model simulations show that most of the produced gas originates from the bicarbonate, and the ammonium contributes significantly less. The functionality of ammonium as leavening agent is not quite clear, but it may help in reducing sodium levels.

Investigation of Structural Transformations During the Manufacturing of Expanded Snacks for Reformulation Purposes

In this paper, we investigate the functionality of potato-based ingredients present in indirectly expanded snacks via careful analysis of their transformation during processing. This research is driven by the desire of industry to develop similar snacks for upcoming markets, where the potato-based ingredients are replaced by other starch sources, which are locally available and at a lower cost. For a range of reformulated snacks, the transformations of starchy ingredients are analysed with a wide variety of experimental methods, like DSC, XRD, and XRT. Our analysis shows that ingredients undergo little transformations during extrusion, which is indeed intended to be mild. During frying native tuber starches (potato and tapioca starch) fully gelatinize, while cereal starches show little gelatinization and swelling. Despite the gelatinization of tuber starches, the particulate character of ingredients is retained. Replacement of pregelatinized potato starch with other starches shows little change in structure. The evolution of the structure of the reformulated snacks are analysed with the CDS formalism. We conclude that gel formers and hard fillers present in the analysed formulations had little functionality regarding texture or structure. For texture, it appears to be required that the matrix composes of a bicontinuous structure of soft fillers, namely gelatinized tuber starches and potato dehydrates. Both these ingredients can be replaced by other tuber-starch sources if the aggregation of the two soft fillers can be prevented. Commercial availability of tuber flours can still be an issue.

Understanding functionality of sucrose in cake for reformulation purposes

We review the functionality of sucrose during the manufacture of cakes from the perspective of sugar replacement. Besides providing sweetness, sucrose has important functionalities concerning structure formation. These functionalities also need to be mimicked in reformulated cakes. First, we review the hypotheses, concerning the development of structure and texture of cakes during manufacturing, which are conveniently summarized in a qualitative way using the Complex Dispersed Systems methodology. Subsequently, we represent the changes of the state of the cake during manufacturing in a supplemented state diagram, which indicates the important phase transitions occurring during baking. From the analysis, we have learned that sucrose act both as a plasticizer and as a humectant, modifying the phase transitions of biopolymers, dough viscosity, and water activity. If sugar replacers exactly mimick this behavior of sucrose, similar textures in reformulated cakes can be obtained. Physical theories exist for characterizing the plasticizing and hygroscopic behavior of sugars and their replacers. We have shown that the starch gelatinization and egg white denaturation can be predicted by the volumetric density of hydrogen bonds present in the solvent, consisting of water, sugar or its replacers, such as polyols or amino-acids.

Understanding functionality of sucrose in biscuits for reformulation purposes

We review the functionality of sucrose during the manufacture of biscuits from the perspective of sugar replacement. Besides to providing sweetness, sucrose has important functionalities concerning structure and texture formation. These functionalities also need to be mimicked in reformulated biscuits. First, we review the hypotheses concerning the development of structure and texture of biscuits during manufacturing, which are conveniently summarized in a qualitative way using the Complex Dispersed Systems methodology. Subsequently, we represent the changes of the state of the biscuit during manufacturing in the supplemented state diagram, which indicates the important phase transitions occurring during mixing and baking. We propose that when reformulated biscuits follow similar paths in the state diagram, similar structures and textures can be obtained. Physical theories exist for predicting these phase transitions for existing sucrose-rich biscuits and also reformulated biscuits containing extensive sweeteners as sugar replacers. More accurate predictions of structure and texture can be eventually obtained if they are combined with computational models, including heat and moisture transfer.

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.