Objective Rollability Method for Corn Tortilla Texture Measurement

An objective rollability method that imitates subjective rollability scores of corn tortilla texture was developed. Force and work required to pull an axle that caused a tortilla to roll around a dowel were measured. The sensitivity of the technique to detect changes in corn tortilla texture during storage was evaluated, and other factors affecting objective rollability and tortilla texture were studied. The objective rollability technique was fast, simple, and sensitive to changes in the tortillas, and worked effectively on commercial samples. Data was significantly correlated to subjective rollability and flexibility scores. Textural differences among fresh tortillas during the first 24 hr of storage, and among tortillas with different thicknesses and additives, were detected by the objective rollability method. Thicker tortillas required more force and work to roll than thin tortillas. The objective technique is more sensitive to changes in texture than subjective evaluations, which do not detect differences in tortilla variability during the first 24 hr after baking, and it can be used to evaluate the effect of formulation and processing changes on fresh and stored tortillas.     

Use of Extensibility to Measure Corn Tortilla Texture

An objective extensibility test was evaluated to measure texture of corn tortillas. A tortilla strip is pulled apart by a tensile force during the test. Force at 1 mm deformation, force required to rupture the tortilla strip, modulus of deformation, and extensibility distance were correlated to subjective rollability and flexibility scores. Hard, firm tortillas required more force to deform and to rupture and had greater moduli of deformation than soft, flexible tortillas. Tortilla texture was affected by manufacturer of commercial tortillas and by aging. The coefficient of variation ranged from 6.0 to 16.7% for force at 1 mm deformation and work required to rupture, respectively. The extensibility technique is sensitive, fast, simple, and repeatable.     

Effect of Infrared Baking on Wheat Flour Tortilla Characteristics

A new and improved method for baking wheat flour tortillas was evaluated. The method was faster and reduced tortilla dehydration. The aim of the study was to evaluate the efficiency of the infrared baking method on rollability, puffing, layering, color (lightness), and texture (cutting force and tensile strength) characteristics of wheat tortillas formulated and formed by the traditional (hand-rolled) and commercial (hot-press) methods. These tortillas were also compared with traditional tortillas cooked on a hot griddle and commercial tortillas cooked in a three-tier, gas-fired oven. In the infrared radiation (IR) method, tortillas were baked for 17 or 19 sec by IR using black-body radiation at a selected wavelength band and emission temperatures of 549 or 584°C. IR-baked tortillas showed good characteristics of rollability, puffing, layering, color, and texture. The loss of moisture during baking of the tortillas formed by hot-pressing and baked by IR was significantly lower than that of tortillas baked by traditional and commercial methods. X-ray diffraction of tortillas prepared by the traditional process and baked by the IR method showed a pattern similar to that of homemade tortillas baked on a hot griddle. The average energy used by the IR oven was less than that used in the commercial method which, in turn, is more efficient than the traditional hot griddle method.     

Effects of Resistant Starch and Fiber from High‐Amylose Non‐Floury Corn on Tortilla Texture

A high‐amylose, non‐floury corn, a floury corn, and a 1:1 blend were made into masa and then tortillas. The masa flour made with the high‐amylose corn had a greater amount of resistant starch (RS 28.8%) and a greater amount of total dietary fiber (TDF 42.1%) than that with the floury corn (RS 2.9%, TDF 9.6%), producing a high‐fiber tortilla. The masa was evaluated for pasting properties using a Rapid ViscoAnalyser (RVA). The high‐amylose masa slurry gelatinized little at 95°C. The floury masa had the greatest peak viscosity, whereas the 1:1 blend was intermediate in value. Sensory evaluations of the tortillas for the textural attributes showed the floury tortillas to be chewier, more rollable, and grittier than the high‐amylose tortillas, whereas the blend tortillas were intermediate for most attributes. The cutting force of the high‐amylose tortillas, measured on a texture analyzer, was very low; the blend and floury tortillas required more force. Chewiness was correlated to rollability (r = 0.99, P = 0.05). The %RS and %TDF were correlated to rollability (r = –0.99), and cutting force (r = 0.99). The floury and blend tortillas had firm textures expected of desirable tortillas, whereas the high‐amylose tortillas broke under little force, and would not roll. The high‐amylose tortillas had high amounts of RS and TDF but poor texture. The blend tortillas retained most floury tortilla textural properties, making them suitable products for consumer use.     

Textural Studies of Stored Corn Tortillas with Added Xanthan Gum

Nixtamalized corn flour for tortilla preparation had added xanthan gum at different concentrations. Rollability, puncture, and extensibility tests using a texture analyzer machine measured the effect of xanthan gum on the staling of corn tortillas. Rollability, puncture, and extensibility tests were simple, fast, and repeatable. The rollability parameters showed that the addition of gum produced more flexible tortillas with decreased staling. The addition of hydrocolloid decreased the force required to penetrate the tortilla, but this parameter was slightly increased when storage time increased. The parameters determined in the extensibility test showed textural differences because the fresh tortillas had a higher distance of extensibility and this parameter decreased when storage time increased. Untreated stored tortillas presented a higher modulus of deformation, work, and rupture force values. However, the addition of xanthan gum decreased these values. The addition of hydrocolloid to tortilla decreased the hardness and increased the flexibility and rubbery characteristics of tortillas.     

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.     

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 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.     

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.     

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.     

Folate Stability in Folic Acid Enriched Corn Masa Flour,Tortillas, and Tortilla Chips over the Expected Shelf Life

Neural tube defects occur at higher rates in Hispanic populations in the United States. Such populations would benefit from folic acid fortification of corn masa flour (CMF). This study evaluated folate stability in fortified CMFs and tortillas and tortilla chips made therefrom. There was no significant loss of folate during the six‐month shelf life of fortified tortilla CMF and tortilla chip CMF. There was a 13% loss (P < 0.05) of folate during tortilla baking and no loss during tortilla chip frying. Both tortillas and tortilla chips showed significant folate losses over the two‐month shelf life for these products, with a 17% loss in fortified tortillas and a 9% loss in tortilla chips. Folate in fortified CMFs, tortillas, and tortilla chips is relatively stable and comparable to the stability of folate in wheat flour and breads.     

Wheat Tortilla Quality: Impact of Amylose Content Adjustments Using Waxy Wheat Flour

Amylose content is closely related to wheat flour pasting or thermal properties, and thus affects final food qualities. Fourteen flour blends with amylose content ranges of <1 to 29% were used to study tortilla production and quality parameters. Reduced amylose contents decreased dough stickiness and pliability; low amylose doughs were also very smooth in appearance. Very low flour amylose content was associated with earlier tortilla puffing and poor machinability during baking, darker color, low opacity, larger diameters, and reduced flexibility after storage. Tortilla texture analysis indicated that lowering amylose content gave fresh tortillas higher extensibility; after three or more days storage, however, low amylose flours required more force to break the tortillas and the rupture distances became shorter. These results, as reflected in covariate analysis, were not significantly affected by the flour blend's protein content, swelling volume/power, SDS‐sedimentation volume, mixograph dough development time, or mixograph tolerance score. Based on our observation of an initial increase in extensibility with reduced‐amylose tortillas, adding 10–20% waxy flour into wild‐type flours should be ideal for restaurant (on‐site) tortilla production or circumstances where tortillas are consumed shortly (within a day) after production. The optimal flour amylose content for hot‐press wheat tortilla products is 24–26%.     

Functionality of Rice and Sorghum Flours in Baked Tortilla and Corn Chips

The effects of raw and gelatinized sorghum and rice flours on the structure and texture of baked corn and tortilla chips were evaluated. Dry masa flour was hydrated into masa, sheeted, and cut. Corn chips were baked in an air-impingement oven, and tortilla chips were baked first in a three-tier oven and then in an air-impingement oven. Baked tortilla chips required significantly greater force to break and were less susceptible to breakage during handling than baked corn chips. Raw and gelatinized, normal and waxy rice and sorghum flours significantly changed the texture and structure of baked chips. Waxy rice and sorghum flours reduced peak force and work, increased chip thickness, and improved overall acceptability (as assessed by a taste panel), but waxy rice and sorghum chips were more fragile and had a greater number of large central air cells. Waxy rice was more beneficial than waxy sorghum flour. Gelatinization of waxy flours increased thickness of baked chips, whereas gelatinization of nonwaxy flours had no improvement over waxy flours alone. Gelatinization of sorghum flour significantly decreased the peak force and work values for baked tortilla chips when compared with the control chips. Gelatinized rice flour tortilla chips were not significantly different than the control chips but were significantly harder than the other baked tortilla chips. The complex interactions that occur in baked corn and baked tortilla chips suggest that each ingredient acts differently in the two products. Thus, each ingredient must be evaluated for specific products and processes.     

Role of Gluten in Flour Tortilla Staling

Effects of protease and transglutaminase (TG) on dough and tortilla microstructures, shelf‐stability, and protein profile were determined to infer the role of gluten in tortilla staling. Control and enzyme‐treated tortillas were prepared using a standard bake test procedure and evaluated for three weeks. Confocal micrographs of control dough showed thin protein strands forming a continuous web‐like matrix. Protease‐treated dough had pieces of proteins in place of the continuous matrix, while TG‐treated dough had thicker protein strands that were heterogeneously distributed. Control tortillas had a well‐distributed continuous protein structure. Protease‐treated tortilla had a continuous structure despite being composed of hydrolyzed proteins in the dough, while the TG‐treated tortilla retained clumps of proteins. Both treatments resulted in shorter shelf‐stability of tortillas. An evenly distributed and moderately stronger gluten network is necessary for longer retention of tortilla flexibility. Solubility of protein fractions differed among treatments, but molecular weight distribution did not differentiate control and treated dough or tortillas. The proportion of each protein fraction appears to affect staling.     

Objective Texture Measurements of Commercial Wheat Flour Tortillas

Texture is a property of major importance in the evaluation of baked products. To determine a sample of commercial ranges for stretchability, rollability, firmness, and Kramer shear cell measurements for wheat flour tortillas using the TA‐XT2 texture analyzer, three separate sets of five tortilla brands purchased from stores in Manhattan, KS, were evaluated. Two brands had two formulations, regular and fat‐free. Significant differences (P < 0.05) in stretchability, firmness, and Kramer shear cell occurred between regular and fat‐free tortillas of one tortilla brand. Significant differences (P < 0.05) also were found among the sets of some tortilla brands. Kramer shear cell and stretchability measurements are recommended because Kramer shear cell measures the force combined with compression, shearing, and extrusion. Stretchability measurements were repeatable and are an important textural property of wheat flour tortillas. Ranges for textural properties for commercial wheat flour tortillas were determined, as well as the variability of the textural methods used.     

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.     

Effect of Micronutrient Fortification on Nutritional and Other Properties of Nixtamal Tortillas

Nixtamalization is the process of steeping dried corn in hot water with calcium hydroxide (lime) with subsequent removal of all or most of the pericarp through washing. The resulting product is called nixtamal. Approximately 60% of corn tortillas in Mexico are produced from nixtamal, with the remainder prepared from nixtamalized corn flour. Nixtamal was fortified with micronutrient premix containing iron, zinc, folic acid, niacin, riboflavin, and thiamin. Premix composition followed a proposed Mexican regulation for corn flour fortification, adjusted for moisture. Effects of premix on masa adhesiveness, hardness, and pH, as well as tortilla sensory properties, stretchability, rollability, and color were measured. Micronutrient levels were tested in the dry corn, nixtamal, masa, and tortillas. There were no significant differences in masa texture or pH, tortilla rollability, or consumer acceptance of tortillas when comparing unfortified control and fortified treatments. Added thiamin was almost entirely degraded during processing. Folic acid and riboflavin decreased 26 and 45%, respectively, through the masa‐tortilla manufacturing process. Niacin showed no significant loss. Despite processing losses, fortification resulted in significant nutrient increases compared with control tortillas. Folic acid increased 974%, riboflavin increased 300%, niacin increased 141%, iron increased 156%, and zinc increased 153% in fortified tortillas.     

Alkaline Processing (Nixtamalization) of White Mexican Corn Hybrids for Tortilla Production: Significance of Corn Physicochemical Characteristics and Process Conditions

Five white corn hybrids were processed (nixtamalized) using 10 different processing conditions; tortillas were prepared to establish relationships between corn composition, physical characteristics, and nixtamalization process or product properties. Corn hybrids were characterized by proximate analysis and by measuring Stenvert hardness, Wisconsin breakage, percent floaters, TADD overs, thousand‐kernel weight, and test weight. Corn characteristics were correlated with process and product variables (effluent dry matter loss and pH; nixtamal moisture and color; masa moisture, color, and texture; and tortilla moisture, color, and rollability). Process and product variables such as corn solid loss, nixtamal moisture, masa texture, and tortilla color were influenced not only by processing parameters (cook temperature, cook time, and steep time) but also depended on corn characteristics. Significant regression equations were developed for nixtamalization dry matter loss (P < 0.05, r² = 0.79), nixtamal moisture (P < 0.05, r² = 0.78), masa gumminess (P < 0.05, r² = 0.78), tortilla texture (P < 0.05, r² = 0.77), tortilla moisture (P < 0.05, r² = 0.80), tortilla calcium (P < 0.05, r² = 0.93), and tortilla color a value (P < 0.05, r² = 0.87).     

In Vitro Starch Digestibility of Tortillas Elaborated by Different Masa Preparation Procedures

Starch digestibility was evaluated in freshly prepared tortillas elaborated from masa obtained from different procedures (laboratory‐made masa, commercial masa, and nixtamalized corn flour) and from laboratory‐made masa with added commercial hydrocolloid, and stored for 24, 48, and 74 hr. Tortillas prepared with commercial masa had the highest available starch (AS) content and the commercial tortillas had the lowest, showing a decrease in AS content when storage time increased. Tortilla of commercial masa showed the lowest resistant starch (RS) content that agrees with the AS measured. However, tortilla of laboratory‐made masa presented the highest AS and RS contents. RS increased with storage time, a pattern that is related to the starch retrogradation phenomenon observed when retrograded resistant starch (RRS) was quantified. Commercial tortillas showed predicted glycemic index (pGI) values of 62–75% using a chewing/dialysis procedure (semi in vitro method). Index values were lower than those determined in vitro. The pGI of tortillas decreased, and the values were different depending on the method used to prepare the masa and tortilla. Commercial tortilla and tortilla of NCF had the lowest pGI. Therefore, the procedure to obtain masa and thereafter obtain tortillas influenced the starch digestibility of the product.