Factors Influencing the Microwave-Induced Expansion of Starch-Based Extruded Pellets under Vacuum

The art and science of porous starch: understanding the preparation method and structure-function relationship

Porous starch (PS), a modified form of starch with unique properties, is attracting substantial attention for its diverse advantages and applications. Its intricate porous structure, crystalline and amorphous characteristics, and hydrophilic-hydrophobic properties stem from pore formation via physical, chemical, enzymatic, and combined synergistic methods. Porous starch offers benefits like improved gelatinization temperature, water absorption, increased surface area, tunable crystallinity, and enhanced functional properties, making it appealing for diverse food industry applications. To optimize its properties, determining the parameters governing porous structure formation is crucial. Factors such as processing conditions, starch source, and modification methods substantially impact porosity and the overall characteristics of the material. Understanding and controlling these parameters allows customization for specific applications, from pharmaceutical drug delivery systems to enhancing texture and moisture retention in food products. To date, studies shedding light on how porosity formation can be fine-tuned for specific applications are fewer. This review critically assesses the existing reports on porous starch, focusing on how preparation methods affect porosity formation, thereby influencing the product's crystallinity/hydrophilic-hydrophobic nature and overall applicability.

Expanded porous-starch matrix as an alternative to porous starch granule: Present status, challenges, and future prospects

Exposing the hydrated-soft-starch matrix of intact grain or reconstituted flour dough to a high-temperature-short-time (HTST) leads to rapid vapor generation that facilitates high-pressure build-up in its elastic matrix linked to large deformation and expansion. The expanded starch matrix at high temperatures dries up quickly by flash vaporization of water, which causes loss of its structural flexibility and imparts a porous and rigid structure of the expanded porous starch matrix (EPSM). EPSM, with abundant pores in its construction, offers adsorptive effectiveness, solubility, swelling ability, mechanical strength, and thermal stability. It can be a sustainable and easy-to-construct alternative to porous starch (PS) in food and pharmaceutical applications. This review is a comparative study of PS and EPSM on their preparation methods, structure, and physicochemical properties, finding compatibility and addressing challenges in recommending EPSM as an alternative to PS in adsorbing, dispersing, stabilizing, and delivering active ingredients in a controlled and efficient way.

Structure and Texture Characteristics of Novel Snacks Expanded by Various Methods

The aim of this work was to evaluate the structure of novel potato-based snack foods supplemented with various levels of fresh carrot pulp by using X-ray micro-computed tomography, texture profile, and sensory analysis. Three different methods of extruded snack pellets expansion were used to obtain ready-to-eat crisps: deep-fat frying, microwave, and hot-air toasting. The obtained results revealed that the pellets expansion method affected the porosity, size of pores and wall thickness, texture properties, and notes of sensory analyses of the obtained crisps. Deep-fat frying had a similar influence to microwave heating on ready-to-eat crisps properties, and both methods were significantly different in comparison to hot-air toasting. Crisps based on snack pellets supplemented with the addition of fresh carrot pulp in the amount of 10 to 30% expansion through hot-air heating showed unsatisfactory expansion and texture, but it is highly advisable to use deep-fat frying and microwave heating to achieve attractive potato-carrot crisps.

Characteristics of Newly Developed Extruded Products Supplemented with Plants in a Form of Microwave-Expanded Snacks

The following research focuses on the possibility of applying fresh plant material as a carrot pulp to supplement newly developed extruded products in the form of pellets and microwave-expanded snacks. Fresh carrot pulp, as a valuable vegetable ingredient, was used in the amount of 2.5 g/100 g to 30.0 g/100 g in a potato-based recipe. The snack pellets were processed via extrusion-cooking, using a single-screw extruder with a plasticizing unit L/D = 18, and the use of variable screw speeds. The produced pellets underwent microwave expansion to limit the fat content, so as to produce ready-to-eat (RTE) snacks. The pellets and snacks were tested for nutritional value, as well as for selected quality features: physical properties, structure, pasting characteristics, and texture profile, and PCA analysis and a correlation matrix were performed on the obtained results. Microwave expansion of pellets increased the total phenolic content, the antioxidant activity, water absorption index and lightness of snacks, but decreased the bulk density and setback values of the expanded products when compared to pellets. Generally, we found that it was possible to use up to 30.0 g/100 g of fresh carrot pulp with a positive effect on nutritional value, and without negative effects on the physical properties of extruded products. Both the extrusion-cooking and microwave expansion can minimize the negative impact on plant materials, due to the short processing time.

Microwave Foaming of Materials: An Emerging Field

In the last two decades, the application of microwave heating to the processing of materials has to become increasingly widespread. Microwave-assisted foaming processes show promise for industrial commercialization due to the potential advantages that microwaves have shown compared to conventional methods. These include reducing process time, improved energy efficiency, solvent-free foaming, reduced processing steps, and improved product quality. However, the interaction of microwave energy with foaming materials, the effects of critical processing factors on microwave foaming behavior, and the foamed product's final properties are still not well-explored. This article reviews the mechanism and principles of microwave foaming of different materials. The article critically evaluates the impact of influential foaming parameters such as blowing agent, viscosity, precursor properties, microwave conditions, additives, and filler on the interaction of microwave, foaming material, physical (expansion, cellular structure, and density), mechanical, and thermal properties of the resultant foamed product. Finally, the key challenges and opportunities for developing industrial microwave foaming processes are identified, and areas for potential future research works are highlighted.