Extrusion of Regular and Waxy Barley Flours for Production of Expanded Cereals

Grains of two regular and two waxy barley cultivars were milled into break and reduction stream flours using a wheat milling mill, granulated to facilitate feeding and flow through the barrel, and extruded to form expanded products using a modified laboratory single‐screw extruder. As moisture content of barley granules decreased from 21 to 17%, the expansion index of extrudates increased from 1.81 to 2.68, while apparent modulus of compression work (AMCW) decreased from 17.1 × 10⁴ to 7.8 × 10⁴ N/m². Break stream flours of both regular and waxy barley produced extrudates with higher expansion index (2.72–3.02), higher water absorption index (WAI), and lower AMCW than extrudates from reduction stream flours. Extrudates produced from regular barley had generally higher expansion and lower density than those produced from waxy barley. The specific mechanical energy (SME) was greater during extrusion of regular than of waxy barley. Barrel temperatures of 130, 150, and 170°C for the feeding, compression, and metering sections, respectively, resulted in higher SME, higher expansion index, lower water absorption index and lower AMCW of extrudates compared with a constant extruder barrel temperature of 160°C. Increased screw speed generally resulted in larger expansion index and increased WAI of extrudates. With increased feed rate from 89 to 96 g/min, the expansion index of extrudates decreased from 3.20 to 2.78 in regular barley and 3.23 to 2.72 in waxy barley, and harder extrudates were produced.     

Effects of Extrusion on Dietary Fiber and Isoflavone Contents of Wheat Extrudates Enriched with Wet Okara

Okara is the residue left after soymilk or tofu production. In North America, okara is used either as animal feed, fertilizer, or landfill. The purpose of this study was to use wet okara to produce and enrich extruded cereal products and to study the effects of extrusion on the dietary fiber and isoflavone contents. Wet okara was combined with soft wheat flour to produce two different formulations (33.3 and 40% okara) and extruded using four combinations of two screw configurations and two temperature profiles. Various physicochemical properties, dietary fiber by enzymatic-gravimetric method, and isoflavone content by HPLC were analyzed. The radial expansion ratio decreased as fiber content increased. On the other hand, both bulk density and breaking strength increased as fiber content increased. Combining okara with soft wheat flour resulted in increased protein, dietary fiber, and isoflavone contents compared with soft wheat flour alone. Extrusion of the formulations resulted in decreased insoluble fiber (≤25.5%) and increased soluble fiber (≤150%) contents of extrudates. Extrusion decreased the total detectable isoflavones (≤20%) and altered the distribution of the six detected isoflavones.     

Effects of Calcium Hydroxide and Processing Conditions on Corn Meal Extrudates

The effects of added calcium hydroxide (0.0, 0.15, 0.25, and 0.35%) and processing conditions, feed moisture content (mc) (16, 18, and 20%) and barrel temperature (130 and 150°C) on characteristics of corn meal extrudates were studied. Extruder screw speed was maintained at 130 rpm. Corn meal was extruded with a single-screw extruder (Brabender model GNF 1014/2) with a screw compression ratio of 3:1. The highest values (P < 0.05) for radial expansion and the lowest values for density and breaking force of extrudates were found for the treatment with 0.00% calcium hydroxide extruded at 16% feed mc and 130°C barrel temperature. This treatment was statistically different from the other treatments. Best values for radial expansion of samples extruded with added calcium hydroxide were for the samples with 0.15% calcium hydroxide at 18% feed mc and 130°C barrel temperature, followed by the sample with 0.35% calcium hydroxide at 16% feed mc and 130°C barrel temperature. Water absorption index and water solubility index were affected by calcium hydroxide and extrusion conditions evaluated. Extrudates had large numbers of flattened and sheared granules. Increases in calcium hydroxide increased extrudate yellowness. The combined action of calcium hydroxide and extrusion conditions completely modified the organized structure of the starch and suggest the formation of a starch-calcium complex (crystalline region). The texture of the extruded products was crispy after puffing.     

Physical Characteristics,Nutritional Quality,and Antioxidant Potential of Extrudates Produced with Polished Rice and Whole Red Bean Flours

In Brazil, rice (Oryza sativa L.) and beans (Phaseolus vulgaris L.) are the basis of the population's diet, and their consumption together is a good strategy to improve protein biological value. The aim of this study was to produce extruded products with whole red bean (WRBF) and polished rice (PRF) flours and to evaluate the effects of extrusion temperature (T) and feed moisture content (FM) on technological properties and total phenolic compounds content. The extrudates were elaborated in a twin‐screw extruder following a 2² central composite rotatable design with FM (15–23%) and T (120–160°C) as independent variables. WRBF and PRF were used at a 1:3 ratio. Amino acid content and profile were evaluated in the optimum extrudate (produced at FM = 19% and T = 140°C). The total phenolic content identified in extruded products was provided by the red bean seed coat, and its quantification suggested the release of bound phenolics with the extrusion process (not temperature dependent). The extrusion of PRF and WRBF, in combination, produced extruded products of high protein quality, being complete in essential amino acids for the diets of people at least 48 months old. The results indicate that legume flours such as WRBF incorporated into rice flour can cause a positive impact on technological, nutritional, and functional quality of extrudates.     

Effect of Barley Flour on Development of Rice‐Based Extruded Snacks

This study was conducted to develop a ready‐to‐eat extruded food using a single‐screw laboratory extruder. Blends of Indian barley and rice were used as the ingredients for extrusion. The effect of extrusion variables and barley‐to‐rice ratio on properties like expansion ratio, bulk density, water absorption index, hardness, β‐glucan, L*, a*, b* values, and pasting characteristics of extruded products were studied. A central composite rotatable design was used to evaluate the effects of operating variables: die temperature (150–200°C), initial feed moisture content (20–40%), screw speed (90–110 rpm), and barley flour (10–30%) on properties like expansion ratio, bulk density, water absorption index (WAI), hardness, β‐glucan, L*, a*, b* values, and sensory and pasting characteristics of extruded products. Die temperature >175°C and feed moisture <30% resulted in a steep increase in expansion ratio and a decrease in bulk density. Barley flour content of 10% and feed moisture content of <20% resulted in an increased hardness value. When barley flour content was 30–40% and feed moisture content was <20%, a steep increase in the WAI was noticed. Viscosity values of extruded products were far less than those of corresponding unprocessed counterparts as evaluated. Rapid visco analysis indicated that the extruded blend starches were partially pregelatinized as a result of the extrusion process. Sensory scores indicated that barley flour content at 20%, feed moisture content at 30%, and die temperature at 175°C resulted in an acceptable product. The prepared product was roasted in oil using a particular spice mix and its sensory and nutritional properties were studied.     

Effect of extrusion temperature on the solubility and molecular weight of lentil bean flour proteins containing low cysteine residues

Lentil flour was extruded at die temperatures of 135, 160, and 175 degrees C. The soluble protein content in the extrudates decreased by 40.1% in the extracting buffer (1% sodium dodecyl sulfate in 50 mM sodium phosphate buffer, pH 6.9) as the extrusion die temperature was increased to 175 degrees C. The most insoluble proteins in the extrudates extruded at die temperatures of up to 175 degrees C could be resolubilized by using sonication. The total disulfide content and sulfhydryl content in the extrudates decreased. The SDS-PAGEs showed that the molecular weight distribution of proteins in the lentil flour changed little before and after extrusion as well as during reduction. The results from this study show that the extrusion temperature had less effect on the solubility and molecular weight of the lentil proteins, which contain a lower level of cysteine residues than wheat proteins.     

Immunochemical and Electrophoretic Analysis of the Modification of Wheat Proteins in Extruded Flour Products

Antibodies specific for wheat proteins were used to identify protein fractions modified during extrusion of Hard Red Spring wheat flour (14% protein) under four different combinations of extrusion conditions (18 and 24% feed moisture and 145 and 175°C die temperature). Antibody binding was assessed on immunoblots of proteins extracted from flour and extrudates separated by SDS‐PAGE. Antibodies to high molecular weight glutenin subunits (HMW‐GS) and to B‐group low molecular weight glutenin subunits (LMW‐GS) recognized intact subunits from both flour and extrudates. Antibodies to C‐group LMW‐GS had diminished binding to extruded proteins. Glutenin‐specific antibodies also recognized protein in the extrudates migrating as a smear at molecular weights higher than intact subunits, indicating cross‐linked proteins. Antibodies recognized albumins or globulins in flour but not in extrudates, evidence that these fractions undergo significant modification during extrusion. Acid‐PAGE and antibody reaction of gliadins extracted in 1M urea and in 70% ethanol revealed total loss of cysteine‐containing α, β, γ‐gliadins but no obvious effects on sulfur‐poor ω‐gliadins, suggesting gliadin modification involves replacing intramolecular disulfides with intermolecular disulfide cross‐links. Identifying protein fractions modified during different extrusion conditions may provide new options for tailoring extrusion to achieve specific textural characteristics.     

Changes in Disulfide and Sulfhydryl Contents and Electrophoretic Patterns of Extruded Wheat Flour Proteins

Twin‐screw extrusion of wheat flour and the effects on the flour proteins were studied using flour samples containing 9, 20, and 30% protein. Vital gluten containing 70% protein was used to achieve the flour protein levels. The three flour samples were extruded with a twin‐screw extruder at a combination of processing parameters (exit die temperatures of 120, 140, and 160°C, and screw speeds of 240, 320, and 400 rpm). Increasing extruder exit die temperatures resulted in increased sulfhydryl content of the 9 and 20% protein content flour samples, but appeared to have little or no effect on the 30% protein content flour sample. Similarly, disulfide content decreased, albeit disproportionately, following the same trend. Both sulfhydryl and disulfide contents of extruded samples were lower than those of the nonextruded samples and could imply denaturation of protein, aggregation through intermolecular disulfide bonds, or oxidation during extrusion processing. Total cysteine content of extruded samples decreased by ≈16% relative to nonextruded samples, but otherwise remained almost unchanged among all extruded samples. The loss of total cysteine in extruded samples could represent the generation of hydrogen sulfide, volatile organic compounds, or flavor compounds during extrusion. SDS‐PAGE analysis of total proteins showed a shift from the higher to lower molecular weight regions for certain protein bands. Both depolymerization and protein aggregation occurred at higher shear forces during extrusion.     

Effect of Extruding Wheat Flour at Lower Temperatures on Physical Attributes of Extrudates and on Thiamin Loss When Using Carbon Dioxide Gas as a Puffing Agent

Wheat flour with 0.3% (w/w) thiamin was extruded on a twin‐screw laboratory‐scale extruder (19‐mm barrel) at lower temperatures and expanded using carbon dioxide (CO₂) gas at 150 psi. Extrusion conditions were die temperature of 80°C and screw speed range of 300–400 rpm. Control samples were extruded at a die temperature of 150°C and screw speed range of 200–300 rpm. Dough moisture content was 22% in control samples and 22 and 25% in CO₂ samples. Expansion ratio, bulk density, WAI, and %WSI were compared between control and treatment. CO₂ injection did not significantly increase expansion ratio. Bulk densities in the CO₂ extruded samples decreased when feed moisture decreased from 25 to 22%. The products using CO₂ had lower WAI values than products puffed without CO₂ at higher temperatures. The mean residence time was longer in CO₂ screw configurations than in conventional screw configurations. Thiamin losses were 10–16% in the control samples. With CO₂, thiamin losses were 3–11% at 22% feed moisture, compared with losses of 24–34% at 25% moisture. Unlike typical high‐temperature extrusion, thiamin loss in the low‐temperature samples decreased with increasing screw speed. Results indicate that thiamin loss at lower extrusion temperatures with CO₂ injection is highly dependent on moisture content.     

Twin-Screw Extrusion Processing of Feed Blends Containing Distillers Dried Grains with Solubles (DDGS)

Extrusion trials were conducted with varying levels of distillers dried grains with solubles (DDGS) along with soy flour, corn flour, fish meal, vitamin mix, mineral mix, and net protein content adjusted to 28% using a Wenger TX-52 twin-screw extruder. The properties of extrudates were studied in experiments conducted using a full-factorial design with three levels of DDGS content, two levels of moisture content, and two levels of screw speed. Increasing the DDGS content from 20 to 60% resulted in a 36.7% decrease in the radial expansion, leading to a 159 and 61.4% increase in the unit density and bulk density of the extrudates, respectively. Increasing the DDGS content resulted in a significant increase in the water absorption index (WAI) but a significant decrease in the water solubility index (WSI) of the extrudates. Changing the screw speed and moisture content had no significant effect on the radial expansion ratio but resulted in a significant difference in the bulk density of the extrudates, which may be due to the occurrence of longitudinal expansion. Even though changing the moisture content and screw speed had no significant effect on the WSI of the extrudates, significant differences in the WAI of the extrudates were observed. The ingredient components in the blend and moisture content had an influence on the color changes of the extrudates, as did the biochemical changes occurring inside the barrel during processing. Overall, it was determined that DDGS could be included at a rate of up to 60% using twin-screw extrusion, and that viable pelleted floating feeds can be produced.     

Effect of Sucrose on Starch Conversion and Glass Transition of Nonexpanded Maize and Wheat Extrudates

Nonexpanded “half products” were prepared by twin‐screw extrusion of maize and wheat of fine and coarse particle size in three levels of sucrose, 0, 10, and 20% db. The degree of starch conversion in the extrudates was determined using X‐ray diffraction, differential scanning calorimetry, and rapid viscosity analysis. Starch conversion was greater in the fine material compared with the coarse material and greater for wheat compared with maize. Sugar addition decreased starch conversion in all cases, but the effect was greater for maize compared with wheat and for the coarse material compared with the fine material. The thermal mechanical properties were studied by dynamic mechanical thermal analysis to determine the effect of sugar on the glass transition temperature (T_g) in the four different materials. As expected, the mechanically determined T_g was reduced by sugar addition. Water plasticized wheat semolina less than the other three materials. It was suggested that this was because the extruded semolina was entirely amorphous, whereas Xray analysis showed some crystallinity in the other three materials. Die swell was much less for maize grits possibly because elasticity decreased with decreasing starch conversion. The implications for the role of both water and sugar on the behavior of directly expanded extrudates are discussed.     

Physical and biochemical properties of maize hardness and extrudates of selected hybrids

Protein and starch determinants of maize kernel hardness and extruded products were characterized to better define the role of endosperm texture during extrusion. Maize physical properties were correlated with total proteins and zein subclasses (p < 0.01). The extrusion process significantly altered protein solubility and increased protein fragmentation as measured by RP-HPLC and size exclusion chromatography. Harder grits and extrudates demonstrated higher amylose content, lower degree of starch damage, and fragmentation at different screw speeds than softer grits and extrudates. Differences in extrudate expansion ratio, water absorption index, water solubility index, oil absorption capacity, and breaking stress between harder and softer hybrids were related to protein aggregation and fragmentation as well as starch damage and fragmentation.     

Effects of Processing Parameters on Physical Properties of Corn Starch Extrudates Expanded Using Supercritical CO2 Injection

Corn starch was extruded with a corotating twin-screw extruder (24:1 L/D ratio, 31-mm screw diameter) and supercritical CO₂ was injected as a blowing agent. The effects of barrel temperature (80–90°C), screw speed (150–250 rpm), and water injection (30–54 g/min) on specific mechanical energy (SME) input for the process and the physical properties of extrudates, such as expansion ratio, water absorption (WA), water solubility (WS), breaking stress, and elastic modulus, were examined using a response surface methodology. Barrel temperature had the greatest effect on physical properties of extrudates but not on SME input, whereas screw speed and water injection had significant effects on SME input. Extrudates had a smooth surface, and air cells were uniform and closed, providing low WA and WS. Using superimposed contour plots, optimum barrel temperature, screw speed, and water injection rate, based on maximum expansion ratio and minimum SME input, were 94–96°C, 155–175 rpm, and 36–39 g/min, respectively.     

Role of Blowing Agents in Expansion of High‐Amylose Starch Acetate During Extrusion

High‐amylose starch acetate (DS 2) was processed in a Brabender twin‐screw extruder with ethanol and isopropanol as blowing agents at concentrations of 0, 2, 5, 10, 15, and 25%. A constant temperature of 150°C, a constant screw speed of 140 rpm, and a die nozzle with diameter of 4.0 mm and length of 16.2 mm were used to study the role of blowing agents on the expansion of the extrudates. Extrudates without blowing agent shrunk considerably after exiting the die as the cells collapsed drastically after expansion. Stable radial expansion of the extrudates increased with increase in the ethanol concentration to an optimum value of 18.0 at 5% (db) ethanol concentration and decreased with further increase in the ethanol concentration. Stable radial expansion increased to a maximum of 17.0 as the concentration of isopropanol was increased to 25% (db), though the rate of increase in expansion decreased with the increase in isopropanol concentration >10%. Flashing off of blowing agents aided in removing the heat generated during extrusion. The faster the extrudate cooled, the less likely it was to shrink. SEM were used to observe the effects of concentration of blowing agents on cell morphology. Various phenomena involved during the expansion are discussed. To obtain an extrudate with high expansion and low density, isopropanol at 15–25% (db) was found most suitable in this study.     

Effects of Extruder Screw Speeds on Physical Properties and In Vitro Starch Hydrolysis of Precooked Pinto,Navy, Red,and Black Bean Extrudates

Precooked pinto, navy, red, and black bean flours were extruded at different screw speeds (320, 380, and 440 rpm) with a twin‐screw extruder. Effect of speed on physical properties and in vitro starch hydrolysis was investigated. Increasing screw speeds reduced water activity, expansion index, and texture. Extrudates could not be obtained from pinto bean flour at 440 rpm because of the high shear effect. Water absorption index and water solubility index were not significantly affected by screw speed but were significantly higher than for unextruded precooked flour. A significant change in color was observed in navy beans, characterized by increasing b values on the Hunter color scale. Resistant starch ranged from 3.65 to 4.83% db and was not significantly affected by screw speed. Glycemic index of all extrudates was high, ranging from 81.3 to 86.9.     

Effects of Starch Amylose Content of Wheat on Textural Properties of White Salted Noodles

White salted noodles were prepared through reconstitution of fractionated flour components with blends of waxy and regular wheat starches to determine the effects of amylose content on textural properties of white salted noodles without interference of protein variation. As the proportion of waxy wheat starch increased from 0 to 52% in starch blends, there were increases in peak viscosity from 210 to 640 BU and decreases in peak temperature from 95.5 to 70.0°C. Water retention capacity of waxy wheat starches (80–81%) was much higher than that of regular wheat starch (55–62%). As the waxy wheat starch ratio increased in the starch blends, there were consistent decreases in hardness of cooked noodles prepared from reconstituted flours, no changes in springiness and increases in cohesiveness. White salted noodles produced from blends of regular and waxy wheat flours became softer as the proportion of waxy wheat flour increased, even when protein content of flour blends increased. Amylose content of starch correlated positively with hardness and negatively with cohesiveness of cooked white salted noodles. Protein content of flour blends correlated negatively with hardness of cooked noodles, which were prepared from blends of regular (10.5% protein) and waxy wheat flours (> 16.4% protein).     

Selected Functional Properties of Extruded Starch Acetate and Natural Fibers Foams

Response surface methodology was employed to study the functional properties of starch acetate foams blended with 0, 7.5, and 15% wood, oat, and cellulose fibers. The blends were extruded with 14, 17, and 20% ethanol as a blowing agent, using a twin‐screw extruder with 160°C barrel temperature and 225 rpm screw speed. Physical characteristics of the extrudates including radial expansion ratio, unit density, and bulk density; and mechanical properties including unit spring index and bulk spring index were determined. Scanning electron micrographs were taken to observe foam cell textures. Higher fiber content resulted in lower radial expansion. Ethanol content had a positive effect on foam expansion. Higher expansion was obtained in starch acetate‐cellulose foams because better starch acetate‐fiber matrix was formed. Mechanical properties increased with higher fiber and ethanol contents. Micrographs showed that uniform cell structures were associated with better mechanical properties.     

Extrusion Chemistry of Wheat Flour Proteins: I. Free Radical Formation

Electron paramagnetic resonance (EPR) spectroscopy was used to study free radical production in hard red wheat flours extruded according to a two-level fractional factorial experimental design (11 and 14% protein content, 160 and 185°C, 16 and 20% moisture, 300 and 500 rpm screw speed, and mass flow rate of 225 and 400 g/min). All spectra showed dominant broad singlets (g = 2.0053–2.0059) from nitrogen-centered radicals originating from heat-induced peptide scission and reactions of lipid radicals with side-chain amino groups. At 77 K, sulfur-oxyl or peroxyl radicals (g = 2.008–2.018), thiyl radicals (g = 2.025), and disulfide radical species (g = 2.032–2.035 and 2.05–2.06), resulting from intra- and intermolecular electron migration and shear-induced scission of disulfides, sometimes were present. The strongest EPR signals occurred under conditions of maximum free radical production and minimum opportunity for radical recombination: high protein flour (14%), high die temperature (180°C), and low moisture (16%). EPR signals correlated with sulfhydryl and disulfide (SH-SS) levels and physical properties of extrudates, indicating that free radicals are integrally involved in molecular changes that occur during extrusion.     

Effect of Extrusion Cooking on the Primary Structure and Water Solubility of β‐Glucans from Regular and Waxy Barley

Water‐soluble β‐glucan from native and extrusion‐cooked barley flours of two barley cultivars, Candle (a waxy starch barley) and Phoenix (a regular starch barley), was isolated and purified. The purity of β‐glucan samples was 85–93% (w/w, dry weight basis) for Candle and 77–86% (w/w, dry weight basis) for Phoenix. The water solubility of β‐glucan (at room temperature, 25°C) in the native and extruded flours (primary solubility) was different from that of the purified β‐glucan samples (secondary solubility). The solubility of β‐glucan in the native and extruded Candle flour was substantially higher than that of β‐glucan in Phoenix. For both cultivars, β‐glucan in the extruded flours had solubility (primary solubility) values higher than in their native counterparts. The solubility of β‐glucan in the purified β‐glucan samples differed depending on the barley cultivar and the extrusion conditions employed. The glycosidic linkage profiles of purified soluble β‐glucan from native and extruded barley flours were determined in order to understand the changes in the primary structure of β‐glucan and the effect of extrusion on the β‐glucan structure‐solubility relationship.     

Effect of Separation and Grinding of Corn Dry-Milled Streams on Physical Properties of Single-Screw Low-Speed Extruded Products

Three streams of corn dry-milled products (corn grits, corn cones, and corn flour) were sieved and separated according to average diameter, and some segregated fractions were ground to produce nine streams. Corn grits were separated to produce grits with diameters of 1.19 and 0.841 mm, and selected fractions were ground into grits with average diameters of 0.297 and 0.210 mm. Corn cones were separated into average diameters of 0.595, 0.420, and 0.297 mm. Corn flour was separated into fractions with average diameters of 0.297 and 0.210 mm. The original and the additional streams were extruded at constant speed (50 rpm) and at three different processing extruder barrel temperature profiles: low (LTP, 100-110-120°C), medium (MTP, 110-120-130°C), and high (HTP, 120-130-140°C). The least significant difference (P < 0.01) test showed that additional grinding of corn grits affects the expansion ratio of extrudates processed at LTP and HTP. Additional separation of corn flour affects (P < 0.01) the bulk density and water solubility index of extrudates at HTP. At HTP, corn cones with diameters of 0.595 mm had significantly (P < 0.01) higher torque, specific mechanical energy, and die pressure than did the original corn cone extrudates without separation.