Effect of Specific Mechanical Energy on Protein Bodies and α-Zeins in Corn Flour Extrudates

Zeins, the storage proteins of corn, are located in spherical entities called protein bodies. The disruption of protein bodies and zein release during extrusion may influence the texture of corn-based extruded foods. In this work, chemical and microscopic studies were conducted on corn flour that had been extruded under mild to extreme conditions to determine the specific mechanical energy (SME) required to break apart protein bodies and release α-zein, and to assess changes in protein-protein interactions. Transmission electron microscopy with immunolocalization of α-zein revealed that starch granules and protein bodies remained intact under mild processing conditions (SME 35–40 kJ/kg), but under harsher conditions, protein bodies were disrupted and α-zein was released. At SME ≈100 kJ/kg, protein bodies appeared highly deformed and fused together with the α-zein released, whereas at higher SME, protein bodies were completely disrupted and α-zein was dispersed and may have formed protein fibrils. Protein in extrudates was less soluble in urea and SDS than in unprocessed corn flour, but it was readily extracted with urea, SDS, and 2-ME. This was likely due to protein aggregation upon processing due to a prevalence of hydrophobic interactions and disulfide bonds. This research directly relates SME during extrusion to chemical and structural changes in corn proteins that may affect the texture of corn-based, ready-to-eat food products.     

Extrusion Chemistry of Wheat Flour Proteins: II. Sulfhydryl-Disulfide Content and Protein Structural Changes

Effects of twin-screw extrusion conditions on wheat flour proteins were studied, using 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, mass flow rate of 225 and 400 g/min). Total protein detectable by solid-phase bicinchoninic acid assay decreased slightly after extrusion, with greatest protein loss at 16% moisture and 160°C. Sulfhydryl content of both flours increased after extrusion at 185°C and 16% moisture with moderate specific mechanical energy (SME ≈ 400–600 kJ/kg) or 160°C and 16% moisture with high SME (SME > 1,000 kJ/kg). Disulfide bonds increased under comparable conditions but with moderate shear (SME = 510–540 kJ/kg). At 20% moisture and either temperature, sulfhydryl and total thiol contents decreased without corresponding increases in disulfides. Reversed-phase HPLC indicated gliadins were the fractions most affected by extrusion; high molecular weight glutenin subunits also were affected. Changes in gliadins were extensive at 185°C and 16% moisture and were minimal at 160°C and 20% moisture. SDS-PAGE confirmed the disappearance of protein bands and appearance of new material at low and high molecular weights, presumably resulting from polypeptide fragmentation followed by random radical recombination. Both protein fragmentation and cross-linking appeared to involve free radicals.     

SME‐Arrhenius Model for WSI of Rice Flour in a Twin‐Screw Extruder

We have modeled a rice extrusion process focusing specifically on the starch gelatinization and water solubility index (WSI) as a function of extrusion system and process parameters. Using a twin‐screw extruder, we examined in detail the effect of screw speed (350–580 rpm), barrel temperature, different screw configurations, and moisture content of rice flour on both extrusion system parameters (product temperature, specific mechanical energy [SME], and residence time distribution [RTD]) and extrudate characteristics (expansion, density, WSI, and water absorption index [WAI]). Changes in WSI were monitored to reveal a relationship between the reaction kinetics during extrusion and WSI. Reaction kinetics models were developed to predict WSI during extrusion. WSI followed a pseudo first‐order reaction kinetics model. It became apparent that the rate constant is a function of both temperature and SME. We have developed an adaptation of the kinetic model based on the Arrhenius equation that shows better correlations with SME and distinguishes data from different screw configurations. This adaptation of the model improved predictability of WSI, thereby linking the extrusion conditions with the extruded product properties.     

Extrusion Conditions Modify Hypocholesterolemic Properties of Wheat Bran Fed to Hamsters

Wheat bran was extruded in a twin‐screw extruder at five specific mechanical energy (SME) levels (0.120, 0.177, 0.234, 0.291, and 0.358 kWh/kg, dwb) and the cholesterol‐lowering effects were compared with those of unprocessed wheat bran when fed to four‐week‐old male golden Syrian hamsters (n = 10/treatment) for three weeks. Diets contained 10% total dietary fiber, 10.3% fat, 3% nitrogen, and 0.4% cholesterol. Plasma total cholesterol and very‐low‐density lipoprotein cholesterol were significantly lower with 0.120 kWh/kg extruded wheat bran diet compared with the unextruded wheat bran control. Total triglycerides were significantly lower with 0.120 and 0.177 kWh/kg wheat bran diets compared with those fed 0.291 and 0.358 kWh/kg extruded wheat bran diets. Cholesterol digestibility, total liver cholesterol, and total liver lipids were significantly lower with all the extruded wheat bran diets compared with the unextruded wheat bran control. Cholesterol digestibility for the 0.291 kWh/kg wheat bran diet was also significantly lower than all other extruded diets. Significantly more sterols were excreted with diets containing 0.291 and 0.358 kWh/kg extruded wheat bran compared with the unextruded wheat bran control. Wheat bran extruded with 0.291 kWh/kg diet resulted in a 13% reduction in plasma cholesterol and a 29% reduction in low‐density lipoprotein cholesterol. Considering lowest cholesterol digestibility, significantly higher sterol excretion, desirable plasma lipo‐protein cholesterol profile, significantly lower liver weight, total liver lipids, and liver cholesterol, the wheat bran extruded at 0.291 kWh/kg appeared to have the most desirable healthful potential. Data suggest that cholesterol‐lowering potential of wheat bran could be enhanced by optimizing the energy input used in the extrusion process.     

Characterization and Optimization of Extrusion Cooking for the Manufacture of Third‐Generation Snacks with Winter Squash (Cucurbita moschata D.) Flour

The aim of this work was to study the effects of barrel temperature (BT, 93.5–140.5°C), feed moisture (FM, 21.3–34.7%), and winter squash flour content (SFC, 0.43–15.6%) on physicochemical properties of microwave‐expanded third‐generation snack foods obtained by extrusion. Physicochemical properties used for optimization were expansion index (EI), penetration force (PF), specific mechanical energy (SME), and total color difference (ΔE). Response surface methodology was used for the analysis of data. The highest values of EI and lowest values of PF were found at high BT and low FM. The lowest values of SME were obtained at high levels of FM throughout the range of BT and SFC, whereas the highest values of ΔE were obtained at high SFC and low FM. Increasing levels of SFC increased ΔE values, whereas EI and SME values decreased. The best processing conditions (EI > 6.0, PF < 9.5 N, SME < 172 kJ/kg, and ΔE < 18) were found in the range of BT, 122–141°C; FM, 24.7–29.5%; and SFC, 0–10.9%. Under optimal process conditions, the retention of total carotenoids was higher than 60%. It is possible to manufacture third‐generation snack foods with good physicochemical properties, which could bring a health benefit because of the presence of carotenoids and dietary fiber in winter squash flour.     

Effect of Some Extrusion Variables on Residual Quantity of Cyanogenic Compounds in an Organic Breakfast Cereal Containing Passion Fruit Fiber

Organic passion fruit fiber is obtained from organic passion fruit rind and is an interesting source of dietary fiber with potential for use in food products such as breakfast cereals. However, various researchers have confirmed the presence of cyanogenic compounds in passion fruit. The objective of this study was to evaluate the effect of the thermoplastic extrusion process on the residual quantity of total cyanogenic compounds (TCC) in extruded organic breakfast cereal produced with corn flour and different levels of passion fruit fiber added to the formulation. For the production of the extrudates, a 2³ complete factorial design was followed, that permitted the analysis of the results by response surface methodology. The effects of the quantity of passion fruit fiber (0–30%), feed moisture content (18–28%) and barrel temperature (120–160°C) on the residual quantity of TCC were studied. The raw passion fruit fiber presented 748.3 mg/kg of TCC. The extruded products presented TCC contents of 0–254.1 mg/kg, increasing significantly with the increase of the quantity of passion fruit fiber. The residual quantity of TCC was influenced by feed moisture, while temperature had no significant effect on this response. Nevertheless, only a small reduction of cyanogenic compounds was verified in the breakfast cereals produced by thermoplastic extrusion. Thus, it was concluded that the toxicity of the cereal blends was not improved by the extrusion process.     

Effect of Specific Mechanical Energy on Properties of Extruded Protein‐Starch Mixtures

The effect of the specific mechanical energy (SME) during extrusion of a protein‐starch mixture was studied by analyzing the glass transition temperature (T_g) and starch gelatinization. We found that the SME values of 344 to 2108 kJ/kg did not significantly change the T_g of the product. To explain the insensitivity of T_g to SME in spite of reported fragmentation taking place during extrusion, we studied the effect of the molecular weight (MW) on T_g in a model system consisting of dextrans of varying molecular weights. We found that the effect of the molecular weight on the T_g reached a plateau at 6.7 × 10⁴. Because the reported size of the fragments created during the extrusion process is larger than this, we were able to explain the apparent insensitivity of T_g to SME in the protein‐carbohydrate matrix studied. However, we found that starch gelatinization varied with SME, the degree of gelatinization being higher for systems exposed to higher SME.     

Extrusion of Cross‐Linked Hydroxypropylated Corn Starches II. Morphological and Molecular Characterization

A series of cross‐linked hydroxypropylated corn starches were extruded with a Leistritz micro‐18 co‐rotating extruder. Extrusion process variables including moisture (30, 35, and 40%), barrel temperature (60, 80, and 100°C), and screw design (low, medium, and high shear) were investigated. Scanning electron microscopy (SEM) of extruded starches showed a gel phase with distorted granules and granule fragments after extrusion at 60°C. After extrusion at 100°C only a gel phase was observed with no granular structures remaining. High performance size exclusion chromatography (HPSEC) equipped with multiangle laser light‐scattering (MALLS) and refractive index (RI) detectors showed extruded starches degraded to different extents, depending on extrusion conditions. The average molecular weight of the amylopectin of unextruded native corn starch was 7.7 × 10⁸. Extrusion at 30% moisture, 100°C, and high shear reduced the molecular weight of amylopectin to 1.0 × 10⁸. Hydroxypropylated normal corn starch extruded at identical conditions showed greater decreases in amylopectin molecular weight. With the addition of cross‐linking, the amylopectin fractions of the extruded starches were less degraded than those of their native and hydroxypropylated corn starch counterparts. Similarly, increasing moisture content during extrusion lowered amylopectin degradation in the extruded starches. Increasing temperature during extrusion of cross‐linked hydroxypropylated starches at high moisture content (e.g., 40%) lowered amylopectin molecular weights of the extruded starches, whereas increasing extrusion temperature at low moisture content (30%) resulted in less degraded molecules. This difference was attributed to the higher glass transition temperatures of the cross‐linked starches.     

Extrusion conditions affect chemical composition and in vitro digestion of select food ingredients

An experiment was conducted to determine the effects of extrusion conditions on chemical composition and in vitro hydrolytic and fermentative digestion of barley grits, cornmeal, oat bran, soybean flour, soybean hulls, and wheat bran. Extrusion conditions altered crude protein, fiber, and starch concentrations of ingredients. Organic matter disappearance (OMD) increased for extruded versus unprocessed samples of barley grits, cornmeal, and soybean flour that had been hydrolytically digested. After 8 h of fermentative digestion, OMD decreased as extrusion conditions intensified for barley grits and cornmeal but increased for oat bran, soybean hulls, and wheat bran. Total short-chain fatty acid production decreased as extrusion conditions intensified for barley grits, soybean hulls, and soybean flour. These data suggest that the effects of extrusion conditions on ingredient composition and digestion are influenced by the unique chemical characteristics of individual substrates.     

南美白对虾太阳能干燥能耗参数优化及中试

为降低南美白对虾干燥能耗,提高南美白对虾干燥品质,该文探讨了实验室太阳能干燥温度、风速及干燥量对干燥效果的影响和中试试验。通过实验室试验确定干燥温度范围为45～55℃,风速6～8 m/s,干燥量3～4 kg,响应面分析法分析了太阳能干燥温度、风速及干燥量与干燥能耗的关系,建立了二次回归模型,确定南美白对虾太阳能干燥最佳工艺参数为：干燥温度为53.40℃,风速为7.43 m/s,干燥量为3.65 kg。在实验室数据的基础上进行了中试试验,结果表明干燥鲜虾量100 kg（煮后69.5 kg）得到38.16 kg产品,所需总能耗549827.05 kJ,其中太阳能提供了379619.05 kJ,实际耗电47.28kW·h（折合能量170208 kJ）。太阳能干燥单位质量（1 kg）南美白对虾实际能耗0.68 kW·h/kg,相比热风纯电加热器干燥节能1.51kW·h/kg,相比燃煤烘房干燥可减少0.75kg/kg CO2排放。该研究结果为南美白对虾太阳能干燥工业化生产提供参考。     

Modifications to physicochemical and nutritional properties of hard-To-cook beans (Phaseolus vulgaris L.) by extrusion cooking.

The objective of this work was to evaluate extrusion cooking as a means to improve the nutritional properties of Phaseolus vulgaris L. that had been stored either at 42 degrees C and 80% relative humidity for 6 weeks or for periods >1 year in cereal stores in tropical conditions. Storage under these conditions resulted in an increase in cooking time increased (7.7- and 12-fold, respectively) as a result of development of the hard-to-cook (HTC) defect. Single-screw extrusion of the milled beans was carried out at four barrel temperatures and two moisture contents. The extrudate bulk density and water solubility index decreased with increasing temperature, whereas the water absorption index increased due to the higher proportion of gelatinized starch in the extruded samples. Both fresh and HTC beans contained nutritionally significant amounts of lectins, trypsin, and alpha-amylase inhibitors, which were mostly inactivated by extrusion. Extrusion also caused a considerable redistribution of insoluble dietary fiber to soluble, although the total dietary fiber content was not affected. Changes in solubility involved pectic polysaccharides, arabinose and uronic acids being the main sugars involved. Stored beans subjected to extrusion cooking showed physical and chemical characteristics similar to those of extrudates from fresh beans.     

Using an In‐Line Slit‐Die Viscometer to Study the Effects of Extrusion Parameters on Corn Melt Rheology

An in‐line slit‐die viscometer (SDV) was used to measure the viscosity of a melt extrudate independently of the extruder operating conditions. The melt produced by extrusion of the corn grits followed a power law rheological model. The viscosity of the melt and extrusion parameters such as specific mechanical energy (SME), torque, and die pressure decreased with increasing moisture content. The degree of starch gelatinization increased when barrel temperature increased from 90 to 130°C. At temperatures higher than 130°C, most of the starch had gelatinized. The increase in barrel temperature, however, resulted in small changes in the apparent viscosity of the melt, until a maximum of ≈130°C. At a constant feed rate, SME increased and torque decreased when screw speed increased due to the shear thinning behavior of the melt. At a constant screw speed, the torque increased and SME decreased with increasing feed rate. This was due to a decrease in apparent viscosity of the melt at higher feed rates. SME is not an independent extrusion variable and should be used with caution either when predicting the effect of thermomechanical treatment of the product or as the key and only variable for controlling the food extrusion process.     

Effects of Feed Rate and Screw Speed on Operating Characteristics and Extrudate Properties During Single-Screw Extrusion Cooking of Rice Flour

Rice flour (37% moisture content) was used to examine the effects of feed rate and screw speed on the specific energy input during single-screw extrusion cooking. Torque, raised by decreasing screw speed or increasing feed rate, was found to be a power law function of the ratio of feed rate to screw speed (F_r/S_s) with r² > 0.94. Specific mechanical energy (SME) calculated from torque also was a power law function of F_r/S_s with r² >0.84 and negative power law indices. The SME obtained was in the 225–481 kJ/kg range. Thus the extruder can be considered low shear. Increasing SME raised the die temperature and decreased both intrinsic viscosity and water absorption index (WAI). The degree of gelatinization and intrinsic viscosity of extrudates also were power law functions of F_r/S_s. The intrinsic viscosity correlated well with the degree of gelatinization, WAI, and cooking loss, and appeared to be a good index of the extrudate properties. Different screw profiles also affect torque measurement.     

Effects of Thermomechanical Extrusion and Particle Size Reduction on Bioconversion Rate of Corn Fiber for Ethanol Production

The objective of this research was to evaluate the effect of thermomechanical extrusion and particle size (PS) reduction on the bioconversion rate of corn fiber for ethanol production. Extrusion was conducted at a screw speed of 300 rpm, feed rate of 120 g/min, feed moisture content of 30%, melt temperature of 140°C, and die diameter of 3 mm. Raw and extruded corn fiber were separated into three different PSs (1 > PS ≥ 0.5, 0.5 > PS ≥ 0.3, and 0.3 > PS ≥ 0.15 mm) with a wire sieve. Extrusion pretreatment and PS reduction resulted in a significant (P < 0.05) difference in physical properties and color values of extruded corn fiber as a result of accelerated degradation of corn fiber structure. Significant increase in water solubility index of extruded corn fiber at 0.3 > PS ≥ 0.15 mm was an indication of high degradation of starch during extrusion for higher release of polysaccharides. Moreover, extruded corn fiber at PS reduction 0.3 > PS ≥ 0.15 mm also significantly increased (P < 0.05) ethanol yield (69.11 g/L) and conversion (68.18%) by increasing protein digestibility and free amino nitrogen, which are essential for higher fermentation efficiency.     

Hydrolysis and Fermentation of Pericarp and Endosperm Fibers Recovered from Enzymatic Corn Dry‐Grind Process

A modified dry‐grind corn process has been developed that allows recovery of both pericarp and endosperm fibers as coproducts at the front end of the process before fermentation. The modified process is called enzymatic milling (E‐Mill) dry‐grind process. In a conventional dry‐grind corn process, only the starch component of the corn kernel is converted into ethanol. Additional ethanol can be produced from corn if the fiber component can also be converted into ethanol. In this study, pericarp and endosperm fibers recovered in the E‐Mill dry‐grind process were evaluated as a potential ethanol feedstock. Both fractions were tested for fermentability and potential ethanol yield. Total ethanol yield recovered from corn by fermenting starch, pericarp, and endosperm fibers was also determined. Results show that endosperm fiber produced 20.5% more ethanol than pericarp fiber on a g/100 g of fiber basis. Total ethanol yield obtained by fermenting starch and both fiber fractions was 0.370 L/kg compared with ethanol yield of 0.334 L/kg obtained by fermenting starch alone.     

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.     

Reduction of fumonisin B1 in corn grits by single-screw extrusion

This study was designed to determine the efficacy of extrusion in reducing fumonisin B1 in corn flaking grits in the presence and absence of glucose. In addition, degradation products of fumonisin B1 during extrusion were identified and quantitated with a mass balance approach. Uncontaminated clean corn grits, grits spiked with 30 microg/g fumonisin B1, and grits fermented with Fusarium verticillioides M-2552 (40-50 microg/g fumonisin B1) were extruded in the presence and absence of glucose (10%, w/w) using a single-screw extruder. Extrusion decreased fumonisin B1 by 21-37%, whereas the same process with added glucose further decreased fumonisin B1 by 77-87%. LC-fluorescence and LC-MS showed that most fumonisin in the extruded samples without added glucose was the fumonisin B1 form, whereas the main degradation product in grits extruded with glucose was N-(deoxy- d-fructos-1-yl)fumonisin B1. The formation of hydrolyzed fumonisin B1 was not significant during extrusion. Results suggest that extrusion in the presence of glucose may reduce fumonisin B1 in corn grits significantly.     

高含量乳清粉的仔猪配合饲料热特性及调质温度控制

为探究热敏性饲料原料乳清粉及不同含量乳清粉的仔猪配合饲料的热物理特性,该文以仔猪料配方中的4种主要饲料原料玉米、豆粕、乳清粉和鱼粉为研究对象,采用混料设计的方法得到33种不同含量(0～30％)乳清粉的仔猪配合饲料,并利用差示扫描量热法(differential scanning calorimetry,DSC)测定了4种单一原料在25～120℃范围内以及33种仔猪配合饲料在25～110℃范围内的比热,分析了乳清粉及高含量乳清粉(质量分数≥14.548％)的仔猪配合饲料的热变性过程.结果显示:玉米、豆粕和鱼粉的比热分别与温度(25～120℃)呈线性、对数和二次关系,而乳清粉的比热与温度(25～110℃)遵循三次多项式的关系;当配合饲料中含有≥6.25％的乳清粉时,其比热与温度遵循三次多项式的关系;配合饲料的比热显著受温度、原料配比以及二者交互作用的影响(P＜0.001),其中,温度的影响最为显著,而乳清粉含量的影响次之.DSC热焓曲线上,乳清粉在109.79℃会出现吸热峰,为乳清蛋白的热变性导致;而随着温度由20℃升高到110℃,乳清粉颗粒由存在许多凸起与微孔的粗糙表面结构逐渐过渡为光滑、粘结的状态.与乳清粉相似,高含量乳清粉的配合饲料也会在77.95～87.69℃出现吸热峰.在仔猪配合颗粒饲料的加工过程中,为降低乳清蛋白的变性程度、减少环模制粒机的堵机现象,应将调质温度降低至70℃以下为宜.研究结果为高含量乳清粉的仔猪配合饲料的调质、制粒等热处理过程的工艺优化提供理论指导.     

Extrusion of Cross‐Linked Hydroxypropylated Corn Starches I. Pasting Properties

A series of cross‐linked (0, 0.014, 0.018, 0.024, and 0.028% POCl₃, dry starch basis) hydroxypropylated (8%) corn starches were extruded using a Leistritz micro‐18 co‐rotating extruder. Process variables included moisture, barrel temperature, and screw design. Differential scanning calorimetry and X‐ray diffraction studies showed the level of starch crystallinity decreased with increasing severity of extrusion conditions. Pasting properties of the extruded starches were examined using a Rapid Visco Analyser. Pasting profiles of starches extruded at different conditions displayed different hot paste viscosity and final viscosity. Increasing starch moisture content during extrusion and level of cross‐linking increased starch viscosity (P < 0.0001), whereas increasing extrusion temperature and shear decreased starch viscosity (P < 0.0001). Interactions were found between level of cross‐linking and screw design and between extrusion temperature and starch moisture content (P < 0.0001).     

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.