Potential of Triticale as a Substitute for Wheat in Flour Tortilla Production

The potential of triticale as a partial or total substitute for wheat in flour tortilla production was evaluated. Different mixtures of triticale and wheat flours were tested in a typical hot‐press formulation. Both grains yielded similar amounts of flour. Wheat flour contained 1.5% more crude protein, 1.6× more gluten, and produced stronger dough than triticale. Triticale flour significantly reduced optimum water absorption and mix time of blends. Flour tortillas with 100% triticale absorbed 8% less water and required 25% of the mix time of the control wheat flour tortilla. The yield of triticale tortillas was lower than the rest of the tortillas due to lower moisture content and water absorption. Triticale dough balls required less proofing and ruptured during hot pressing, thus producing defective tortillas. The 50:50 flour mixture produced doughs with acceptable rheological properties and good quality tortillas. Addition of 1% vital gluten to the 75:25 triticale‐wheat flour mix or 2% to the 100% triticale flour significantly increased water absorption and mix time and improved dough properties and tortilla yields. Textural studies indicated that increasing levels of triticale flour reduced the force required to rupture tortillas. For all tortilla systems, rupture force gradually increased, and extensibility decreased during seven days of storage at room temperature; the highest rate of change occurred during the first day. Sensory evaluation tests indicated that triticale could substitute for 50% of wheat flour without affecting texture, color, flavor, and overall acceptability of tortillas. For production of 100% triticale flour tortillas, at least 2% vital gluten had to be added to the formulation.     

Effects of Wheat Protein Fractions on Flour Tortilla Quality

Commercial wheat protein fractions (10) were evaluated during processing for quality of tortillas prepared using pastry, tortilla, and bread flours. Protein fractions that separately modify dough resistance and extensibility were evaluated in tortillas to determine whether the proteins could increase diameter, opacity, and shelf stability. Tortillas were prepared using laboratory‐scale, commercial equipment with fixed processing parameters. Dough and tortilla properties were evaluated using analytical methods, a texture analyzer, and subjective methods. Tortillas were stored in plastic bags at 22°C for up to 20 days. Adjustments in water absorption and level of reducing agent were made to normalize differences in functionality of 3% added proteins on dough properties. Tortilla weight, moisture, pH, opacity, and specific volume were not affected by added proteins, except for glutenin and vital wheat gluten treatments, which had decreased opacity in tortillas prepared from pastry flour. Increased insoluble polymeric protein content corresponded to decreased tortilla diameter and improved shelf stability. Treatments yielding tortillas with improved shelf stability and similar tortilla properties were produced when commercially processed vital wheat gluten products, FP600, FP6000, FP5000, or gliadin were added to pastry or tortilla flour. These wheat protein fractions improved processing and tortilla quality of wheat flours, especially pastry flour, by modifying protein content and quality.     

Generation of a Mixolab Profile After the Evaluation of the Functionality of Different Commercial Wheat Flours for Hot‐Press Tortilla Production

Refined wheat flours commercially produced by five different U.S. and Mexican wheat blends intended for tortilla production were tested for quality and then processed into tortillas through the hot‐press forming procedure. Tortilla‐making qualities of the flour samples were evaluated during dough handling, hot pressing, baking, and the first five days on the shelf at room temperature. The predominant variables that affected the flour tortilla performance were wet gluten content, alveograph W (220–303) and P/L (0.70–0.94) parameters, farinograph water absorption (57%) and stability (10.8–18.7 min), starch damage (5.43–6.71%), and size distribution curves (uniform particle distribution). Flours produced from a blend of Dark Northern Spring (80%) and Mexican Rayon (20%) wheat had the highest water absorption, and tortillas obtained from this blend showed the highest diameter and lowest thickness. The whitest and best textured tortillas were obtained from the flour milled from three hard types of Mexican wheat blend. A Mixolab profile was generated from the best tortilla flours, those produced by mills 3 and 4. The Mixolab profile showed that a good flour for hot‐press tortillas had a relatively lower absorption and short dough mix time compared with a bread flour and should have a significantly higher gluten compared with an all‐purpose flour. Compared with bread flour, the tortilla flour had higher retrogradation and viscosity values. The Mixolab profile proved to be a good preliminary test to evaluate flours for hot‐press tortillas.     

Effect of High‐Molecular‐Weight Glutenin Subunit Allelic Composition on Wheat Flour Tortilla Quality

Wheat cultivars possessing quality attributes needed to produce optimum quality tortillas have not been identified. This study investigated the effect of variations in high‐molecular‐weight glutenin subunits encoded at the Glu‐1 loci (Glu‐A1, Glu‐B1, and Glu‐D1) on dough properties and tortilla quality. Flour protein profiles, dough texture, and tortilla physical quality attributes were evaluated. Deletion at Glu‐D1 resulted in reduced insoluble polymeric protein content of flour, reduced dough compression force, and large dough extensibility. These properties produced very large tortillas (181 mm diameter) compared with a control made with commercial tortilla wheat flour (161 mm). Presence of a 7 + 9 allelic pair at Glu‐B1 increased dough strength (largest compression force, reduced extensibility, and small‐diameter tortillas). Deletion at Glu‐A1 produced large tortillas (173 mm) but with unacceptable flexibility during storage (score <3.0 at day 16). In general, presence of 2* at Glu‐A1, in combination with 5 + 10 at Glu‐D1, produced small‐diameter tortillas that required large force to rupture (tough texture). Presence of 2 + 12 alleles instead of 5 + 10 at Glu‐D1 produced tortillas with a good compromise between diameter (>165 mm) and flexibility during storage (>3.0 at day 16). These allele combinations, along with deletion at Glu‐D1, show promise for tortilla wheat development.     

Mechanical Starch Damage Effects on Wheat Flour Tortilla Texture

To investigate the effects of mechanically damaged starch and flour particle size on the texture of fresh and stored flour tortillas, two commercial hard red winter wheat flour samples were reground four times using decreasing roll gaps. Tortillas were made with a modified hot‐press procedure. Texture characteristics were measured after tortillas were stored 2 hr (fresh tortilla), 2 days, and 4 days. Damaged starch and particle size significantly affected (P < 0.05) flour water absorption, dough extensibility and resistance, and dough viscosity. As damaged starch increased and particle size decreased, the flour tortillas became less stretchable, the maximum force of Kramer shear decreased, and firmness and rollability increased. The effects of damaged starch and particle size on stretchability and Kramer shear were greater in fresh tortillas than in stored tortillas and became smaller as the storage time increased. However, the effects of damaged starch and particle size on rollability and firmness were smaller in fresh tortillas than in stored tortillas but became greater as the storage time increased.     

Characteristics of Noodles and Bread Prepared from Double‐Null Partial Waxy Wheat

Double‐null partial waxy wheat (Triticum aestivum L.) flours were used for isolation of starch and preparation of white salted noodles and pan bread. Starch characteristics, textural properties of cooked noodles, and staling properties of bread during storage were determined and compared with those of wheat flours with regular amylose content. Starches isolated from double‐null partial waxy wheat flours contained 15.4–18.9% amylose and exhibited higher peak viscosity than starches of single‐null partial waxy and regular wheat flours, which contained 22.7–25.8% amylose. Despite higher protein content, double‐null partial waxy wheat flours, produced softer, more cohesive and less adhesive noodles than soft white wheat flours. With incorporation of partial waxy prime starches, noodles produced from reconstituted soft white wheat flours became softer, less adhesive, and more cohesive, indicating that partial waxy starches of low amylose content are responsible for the improvement of cooked white salted noodle texture. Partial waxy wheat flours with >15.1% protein produced bread of larger loaf volume and softer bread crumb even after storage than did the hard red spring wheat flour of 15.3% protein. Regardless of whether malt was used, bread baked from double‐null partial waxy wheat flours exhibited a slower firming rate during storage than bread baked from HRS wheat flour.     

Effect of Cross‐Linked Resistant Starch on Wheat Tortilla Quality

Resistant starch (RS) ingredients are an attractive option to increase dietary fiber in baked products. This study determined the effect of two forms of cross‐linked and pregelatinized cross‐linked RS, Fibersym‐RW (Fsym) or FiberRite‐RW (FRite), respectively, from wheat on dough and tortilla quality and acceptability. Refined wheat tortillas with 0% (control) to 15% RS (flour basis) were made using a standard baking process. Tortillas with 100% whole white wheat were also made. Physical and rheological properties of dough and tortillas, and sensory profile of tortillas were evaluated. Dough with whole wheat and 15% FRite were significantly harder and less extensible than the control dough; this was related to high water absorption of these doughs. Tortillas with whole wheat and 10–15% FRite were less puffed and denser than the control; however these levels of FRite significantly increased tortilla weight (by up to 6.2%). Dough and tortillas with Fsym were comparable to the control. Dietary fiber (g/100 g, db) increased from 2.8 ± 0.3 in control to 14.3 ± 0.5 and 13.6 ± 0.5 in 15% Fsym and 15% FRite tortillas, respectively. Tortillas with whole wheat were less acceptable than the control in appearance, flavor, and texture, while tortillas with 15% Fsym had higher overall acceptability than the control. Incorporation of 15% cross‐linked wheat RS to increase tortilla dietary fiber is feasible without negatively affecting dough handling and tortilla quality.     

Characteristics of French Bread Baked from Wheat Flours of Reduced Starch Amylose Content

Wheat genotypes of wild type, partial waxy, and waxy starch were used to determine the influence of starch amylose content on French bread making quality of wheat flour. Starch amylose content and protein content of flours were 25.0–25.4% and 14.3–16.9% for wild type; 21.2 and 14.9% for single null partial waxy; 15.4–17.1% and 13.2–17.6% for double null partial waxy; and 1.8 and 19.3% for waxy starch, respectively. Wheat flours of double null partial waxy starch produced smaller or comparable loaf volume of bread than wheat flours of wild type and single null partial waxy starch. Waxy wheat flour, despite its high protein content, generally produced smaller volume of bread with highly porous, glutinous, and weak crumb than wheat flours of wild type and partial waxy starch. French bread baked from a flour of double null partial waxy starch using the sponge-and-dough method maintained greater crumb moisture content for 24 hr and softer crumb texture for 48 hr of storage compared with bread baked from a flour of wild type starch. In French bread baked using the straight-dough method, double null partial waxy wheat flours with protein content >14.3% exhibited comparable or greater moisture content of bread crumb during 48 hr of storage than wheat flours of wild type starch. While the crumb firmness of bread stored for 48 hr was >11.4 N in wheat flours of wild type starch, it was <10.6 N in single or double null partial waxy flours. Wheat flours of reduced starch amylose content could be desirable for production of French bread with better retained crumb moisture and softness during storage.     

Combining Maltogenic Amylase with CMC or Wheat Gluten to Prevent Amylopectin Recrystallization and Delay Corn Tortilla Staling

Antistaling properties of a bacterial maltogenic amylase, sodium carboxymethylcellulose (CMC), and vital wheat gluten on quality of corn tortillas were evaluated during 14 days of storage. Amylopectin recrystallization was the driving force behind the staling of corn tortillas. Increasing levels of recrystallized amylopectin measured by differential scanning calorimetry (DSC) correlated significantly with increased tortilla stiffness (r = 0.43) and reduction in tortilla pliability (r = ‐0.42) during storage. Maltogenic amylase (275–1,650 activity units) made tortillas less stiff but did not preserve pliability and extensibility as effectively as CMC (0.25–0.5%). The combination of 825 MANU of maltogenic amylase (to interfere with intragranular amylopectin recrystallization) and 0.25% CMC (to create a more flexible intergranular matrix than retrograded amylose and amylopectin) produced less stiff, equally flexible, and less chewy tortillas than did 0.5% CMC. Vital wheat gluten was not as effective as CMC in preserving tortilla flexibility or as good as the maltogenic amylase in reducing stiffness. Further research is required to optimize the addition of maltogenic amylases in continuous processing lines that use fresh masa instead of nixtamalized corn flour (NCF) and to determine how these amylases interfere with amylopectin recrystallization.     

Effect of Partial Waxy Wheat on Processing and Quality of Wheat Flour Tortillas

The processing and quality of wheat flour tortillas prepared with partial waxy and normal flour were evaluated. Control procedures and formula were utilized with water absorption varied to obtain machineable doughs. Amylose content was lower in most partial waxy compared with normal wheats. The type of wheat starch did not affect most dough properties or tortilla diameter. Tortilla height and opacity were adversely affected by the decreased amount of amylose in partial waxy wheats. Sufficient leavening reactions occurred early in baking (after 10 sec) to yield an opaque disk, but some baked tortillas lost opacity and become partially transparent after baking. Starch gelatinizes, disperses, and retrogrades concurrently with the leavening reaction during the short (<30 sec) baking time. Amylose functionality during baking and cooling appears to be involved in the retention of air bubbles in tortillas.     

Qualitative Effect of Added Gluten on Dough Properties and Quality of Chinese Steamed Bread

Glutens isolated from 15 soft red winter (SRW) wheat flours were added into a SRW wheat flour to obtain protein levels of 9.6 and 11.3% for determination of the qualitative effect of added gluten on the dough properties and quality of northern‐style Chinese steamed bread (CSB). Sodium dodecyl sulfate sedimentation (SDSS) volume of the gluten source flour exhibited positive relationships with mixograph absorption, midline peak time (MPT), and midline peak value (MPV) of the gluten‐added flours and with surface smoothness, crumb structure, and total score of CSB prepared from the gluten‐added flours regardless of protein content. Positive correlations were also observed between SDSS volume of the gluten source flour and specific volume and stress relaxation score of CSB prepared from the gluten‐added flours of 11.3% protein. The increase in protein content from 9.6 to 11.3% by gluten addition raised mixograph absorption, MPT, and MPV but had no apparent effect on resistance breakdown, dough maximum force for extension, and extensibility, and it increased CSB specific volume and crumb structure score without affecting surface smoothness, stress relaxation, and total score. Mixograph parameters exhibited significant relationships with CSB total score, indicating that they could be effective predictors of the CSB‐making quality of flours.     

Effect of Flour Extraction Rate on White and Red Winter Wheat Flour Compositions and Tortilla Texture

Wheat flours commercially produced at 74, 80, and 100% extraction rates made from hard white winter wheat (WWF) and hard red winter wheat (WRF) were used to produce tortillas at a commercial-scale level. Flour characteristics for moisture, dry gluten, protein, ash, sedimentation volume, falling number, starch damage, and particle-size distribution were obtained. Farinograms and alveograms were also obtained for flour-water dough. A typical northern Mexican formula was used in the laboratory to test the tortilla-making properties of the flours. Then commercial-scale tortilla-baking trials were run on each flour. The baked tortillas were stored at room and refrigeration temperatures for 0, 1, 2, and 3 days. Maximum stress and rollability were measured every day. Tortilla moisture, color, diameter, weight, and thickness were measured for each treatment. Finally, tortilla acceptability was tested by an untrained sensory panel. Analyses of variance (ANOVA) were performed on the data. WWF had higher protein content, dry gluten, sedimentation volume, and water absorption than the WRF. The WWF was the strongest flour based on farinograph development time and alveograph deformation work. It also produced the most extensible dough measured with the alveograph (P/L). Flour protein and ash contents, water absorption, and tenacity increased directly with the flour extraction rate. Both WWF and WRF performed well in commercial-scale baking trials of tortillas. Tortillas made with both types of flours at 74 and 80% extraction rates had the best firmness and rollability. However, tortillas made with WWF 80% had the best color (highest L value). Tortillas prepared with 100% extraction rate flour were also well accepted by the sensory panel, had good textural characteristics, and became only slightly firm and slightly less rollable after three days of storage at room temperature.     

Rheological and Sensory Evaluation of Wheat Flour Tortillas During Storage

Texture of wheat flour tortillas over 15 days at room temperature was evaluated using an expert sensory panel, consumer panels, subjective rollability test, large deformation rheological methods (i.e., bending, extensibility [1‐D and 2‐D], and puncture tests), and stress relaxation method. Most of the changes in texture occurred during the initial 8 days of storage, while texture of tortillas changed slowly thereafter. Differences in texture between fresh and 1‐day‐old tortillas were detected by many objective rheological methods but not by either sensory panel. The expert sensory panel observed a rapid decrease in tortilla extensibility and an increase in staleness between 1 and 8 days of storage and smaller changes in sensory scores after 8 days of storage. Most objective rheological parameters changed rapidly between 0 and 5 days, and slowly after 5 days of storage. Significant correlations and factor analysis reveal that changes occurring in flour tortillas during staling are estimated better by subjective rollability, sensory evaluation (expert and consumer panels), and 2‐dimensional extensibility test than by other methods. Hence, some rheological methods are useful to estimate sensory properties of flour tortillas.     

Significance of Amylose Content of Wheat Starch on Processing and Textural Properties of Instant Noodles

The effect of amylose content of starch on processing and textural properties of instant noodles was determined using waxy, partial waxy, and regular wheat flours and reconstituted flours with starches of various amylose content (3.0–26.5). Optimum water absorption of instant noodle dough increased with the decrease of amylose content. Instant noodles prepared from waxy and reconstituted wheat flours with ≤12.4% amylose content exhibited thicker strands and higher free lipids content than wheat flours with ≥17.1% amylose content. Instant noodles of ≤12.4% amylose content of starch exhibited numerous bubbles on the surface and stuck together during frying. Lightness of instant noodles increased from 77.3 to 81.4 with the increase of amylose content of starch in reconstituted flours. Cooking time of instant noodles was 4.0–8.0 min in wheat flours and 6.0–12.0 min in reconstituted flours, and constantly increased with the increase in amylose content of starch. Hardness of cooked instant noodles positively correlated with amylose content of starch. Reconstituted flours with ≤12.4% amylose content of starch were higher in cohesiveness than those of wheat flours of wild‐type and partial waxy starches and reconstituted flours with ≥17.1% amylose content. Instant fried noodles prepared from double null partial waxy wheat flour exhibited shorter cooking time, softer texture, and higher fat absorption (1.2%) but similar color and appearance compared with noodles prepared from wheat flour of wild‐type starch.     

Effects of Wheat Starch and Gluten on Tortilla Texture

Wheat starches were isolated from three wheat flours. Two vital wheat glutens, one from a commercial source and another one isolated from straight-grade flour, were combined with wheat starches to form reconstituted flours with a protein level of 10%. Several characteristics of tortillas made with the hot-press method were measured. No significant difference (P < 0.05) occurred in texture of tortillas made with hard wheat gluten and soft wheat gluten. Wheat starches did not have any significant (P < 0.05) effect on tortilla stretchability or foldability. Analysis of variance confirmed that wheat starch and gluten had limited effects on tortilla texture. The possible reasons were that the solubles of wheat flour were not included, and the shortening in the tortilla formula interfered with the interaction of gluten and starch.     

Evaluation of the Functionality of Five Different Soybean Proteins in Hot‐Press Wheat Flour Tortillas

Five different soybean protein sources were added to wheat flour to increase the protein content by 15–25%, and the resulting composite flours were optimally processed into hot‐press tortillas in a pilot plant. The rheological properties of composite flours were evaluated with the farinograph, alveograph, and other wheat quality tests. Tortilla‐making qualities of the control and soybean‐fortified flours were evaluated during dough handling, hot pressing, and baking. The resulting tortillas were tested in terms of yield, physical and chemical parameters, sensory properties, color, and objective and subjective texture. The soybean‐fortified tortillas had increased yields because of the higher dough water absorption and enhanced essential amino acid scores. Among the five different soybean proteins, the defatted soybean flour (SBM1) with the lowest fat absorption index and protein dispersibility index (PDI) and the soybean concentrate produced the best fortified tortillas. The protein meals with high PDI and relatively lower water absorption index (SBM3 and SBM4) produced sticky doughs, lower alveograph P/L values, and defective tortillas. All soybean proteins produced higher yields of tortillas with an enhanced protein quality and amount of dietary fiber.     

Relationship of Dough Extensibility to Dough Strength in a Spring Wheat Cross

A negative relationship between dough strength and dough extensibility would pose a problem for breeding hard wheats, as both dough strength and dough extensibility are desirable. We derived 77 recombinant inbred lines (RIL) from a cross between hard red spring wheat cultivars McNeal and Thatcher. McNeal produces flour with stronger dough and lower extensibility than does Thatcher. RIL were evaluated for strength‐related properties using mixograph analysis and extensibility parameters using the Kieffer attachment to the TA.XT2 texture analyzer. Additionally, the RIL were test baked. Measurements using the mixograph and the Kieffer attachment were highly heritable. Maximum dough extensibility (Ext_max) was negatively correlated with resistance to extension (R_max) (r = ‐0.74) and with mixograph tolerance (r = ‐0.45). Loaf volume was correlated with both R_max (r = 0.42) and area under the extensigraph curve (r = 0.44) based on partial correlation analysis adjusted for protein differences. Ext_max was negatively correlated with loaf volume (r = ‐0.26). The McNeal allele for polymorphism at the Gli1‐B1 locus on chromosome 1BS caused high dough‐mixing tolerance and low dough extensibility. Our results suggest that traditional selection criteria in hard red spring wheat, including tolerance to dough mixing and high loaf volume, may result in reduced dough extensibility.     

Effect of Varying Protein Content and Glutenin-to-Gliadin Ratio on the Functional Properties of Wheat Dough

Gluten, starch, lipids, and water-soluble material were separated from seven wheat samples with a range of protein contents and breadmaking quality. The isolated glutens were further partitioned into gliadin- and gluteninrich fractions using pH precipitation. Protein content and glutenin-togliadin ratio were systematically altered by blending these fractions into the original flours in calculated amounts. Mixing properties, extension-tester parameters, and baking performance of composite flours were determined using small-scale techniques. Results of dough testing with blends of constant glutenin-to-gliadin ratio showed increases in the mixing time, mixograph peak resistance, maximum resistance to extension, extensibility, and loaf volume as the protein content increased. At constant protein content, increases in glutenin-to-gliadin ratio were associated with increases in mixing time, mixograph peak resistance, maximum resistance to extension, and loaf volume, and with decreases in extensibility. Thus, total protein content and glutenin-to-gliadin ratio independently affected dough and baking properties. The results have allowed the separation of the effects of flour protein quantity and composition on breadmaking properties.     

Evaluation of Various Baking Methods for Polished Wheat Flours

Flour qualities of polished wheat flours of three fractions, C‐1 (100–90%), C‐5 (60–50%), and C‐8 (30–0%), obtained from hard‐type wheat grain were used for the evaluation of four kinds of baking methods: optimized straight (OSM), long fermentation (LFM), sponge‐dough (SDM) and no‐time (NTM) methods. The dough stability of C‐5 in farinograph mixing was excellent and the maturity of polished flour doughs during storage in extensigraph was more improved than those of the commercial wheat flour (CW). There were no significant differences in the viscoelastic properties of CW dough after mixing, regardless of the baking method, while those of polished flour doughs were changed by the baking method; this tendency became clear after fermentation. The polished flours could make a better gluten structure in the dough samples after mixing or fermentation using LFM and SDM, as compared with other baking methods. Baking qualities such as specific volume and storage properties of breads from all polished flours made with SDM increased more than with other methods. In addition, viscoelastic properties of C‐5 and C‐8 doughs fermented by SDM were similar to those of CW, and the C‐5 breadcrumb showed softness similar to that of the CW. Also, SDM could make C‐5 bread with significantly higher elasticity and cohesiveness after storage for five days when compared with CW bread. Therefore, SDM with long fermentation, as compared with other baking methods, was considered suitable for use with polished flours to give better effects on dough properties during fermentation, resulting in more favorable bread qualities.     

Effects of Leavening Acids and Dough Temperature in Wheat Flour Tortillas

Functionality of four leavening acids (sodium aluminum phosphate [SALP], sodium aluminum sulfate [SAS], monocalcium phosphate [MCP] and sodium acid pyrophosphate [SAPP‐28]) was evaluated during processing of wheat flour tortillas. Formulas were optimized to yield opaque, large‐diameter tortillas with pH 5.9–6.1. Each leavening acid and sodium bicarbonate was first evaluated at 38°C and then evaluated in combination with fumaric acid at 34 and 38°C. Ionic and pH interactions of leavening salts adversely affected dough properties and resting time. Opacity and pH of tortillas prepared with MCP was lower than for other treatments. Higher dough temperature required more leavening acid and base to compensate for some of the loss of CO₂ incurred during dough mixing and resting at 38°C. The addition of fumaric acid decreased the amount of leavening acid, the dough‐resting time and tortilla pH, and improved storage stability. Combinations of MCP, SALP (or SAS), and fumaric acid produced dough and tortillas with good qualities. Tortillas prepared using SALP (or SAS) and fumaric acid tended to be of better quality.