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.     

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.     

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.     

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 Different Wheat Classes and Their Flour Milling Streams on Textural Properties of Flour Tortillas

Wheat flour tortillas were made from flour streams of three wheat cultivars: Jagger hard red winter wheat, 4AT-9900 hard white winter wheat, and Ernie soft red winter wheat. Wheat samples were milled on a Miag experimental mill. Twelve flour streams and one straight-grade flour were obtained. Tortillas were made from each flour stream and the straightgrade flour by the hot-press method. Tortilla stretchability and foldability were evaluated by a texture analyzer and six panelists, respectively. Flour protein and water absorption affected tortilla texture. The foldability evaluated by panelists was positively correlated with flour protein content, farinograph water absorption, and damaged starch (P < 0.05). The 2BK and 3BK streams of hard wheat produced tortillas with strong stretchability and good foldability. Middling streams of hard wheat yielded tortillas with lighter color and less stretchability. Under the conditions tested in this study, soft wheat flours were not good for producing flour tortillas.     

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.     

Particle Size Effects on the Quality of Flour Tortillas Enriched with Whole Grain Waxy Barley

Wheat tortillas were enriched with whole barley flour (WBF) of different particle sizes including 237 μm (regular [R]), 131 μm (intermediate [IM]), and 68 μm (microground [MG]). Topographical and fluorescent microstructure images of flours, doughs, and tortillas were examined. Flours and tortillas were analyzed for color, protein, ash, starch, moisture, and β‐glucan content. Farinograph testing was conducted on the flour blends. Water activity and texture analyses of tortillas were conducted. A 9‐point hedonic scale was used by 95 untrained panelists to evaluate tortilla appearance, color, flavor, texture, and overall acceptability. Two commercial products (CP) were included in some analyses. As WBF particle size decreased, color was lighter; protein, moisture content and mixing stability decreased; ash, starch content, water absorption and farinograph peak time increased; and β‐glucan content was constant. WBF tortillas were darker than the control (C), while IM and MG tortillas had lower peak forces than C. No flavor differences were reported among C, R, and MG tortillas but higher scores were given to both CP in all attributes tested. Tortillas made with the largest WBF particle size (R) were the most similar in protein content, texture and flavor when compared with C tortillas made with refined bread flour.     

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%.     

Dough and Baking Properties of High‐Amylose and Waxy Wheat Flours

The dough properties and baking qualities of a novel high‐amylose wheat flour (HAWF) and a waxy wheat flour (WWF) (both Triticum aestivum L.) were investigated by comparing them with common wheat flours. HAWF and WWF had more dietary fiber than Chinese Spring flour (CSF), a nonwaxy wheat flour. Also, HAWF contained larger amounts of lipids and proteins than WWF and CSF. There were significant differences in the amylose and amylopectin contents among all samples tested. Farinograph data showed water absorptions of HAWF and WWF were significantly higher than that of CSF, and both flours showed poorer flour qualities than CSF. The dough of WWF was weaker and less stable than that of CSF, whereas HAWF produced a harder and more viscous dough than CSF. Differential scanning calorimetry data showed that starch in HAWF dough gelatinized at a lower temperature in the baking process than the starches in doughs of WWF and CSF. The starch in a WWF suspension had a larger enthalpy of gelatinization than those in HAWF and CSF suspensions. Amylograph data showed that the WWF starch gelatinized faster and had a higher viscosity than that in CSF. The loaves made from WWF and CSF were significantly larger than the loaves made from HAWF. However, the appearance of bread baked with WWF and HAWF was inferior to the appearance of bread baked with CSF. Bread made with WWF became softer than the bread made with CSF after storage, and reheating was more effective in refreshing WWF bread than CSF bread. Moreover, clear differences in dough and bread samples were revealed by scanning electron microscopy. These differences might have some effect on dough and baking qualities.     

End-Use Quality of Flour from Rhyzopertha dominica Infested Wheat

The objective of this study was to evaluate how Rhyzopertha dominica infestation of stored wheat grain affects the rheological and baking properties of bread made with the milled flour. Wheat samples were infested with R. dominica and stored for up to 180 days at room temperature. Every 45 days, samples of wheat were collected and evaluated for insect population and flour yield. Flour milled from these wheat samples was evaluated for color reflectance, pH, fat acidity, and rheological properties which were measured by a farinograph. Loaves of bread were baked using a straight-dough procedure. Volume, height, and weight of the loaves were evaluated. None of the analyses performed on the control wheat flours showed any changes during the storage period, and they were similar to the initial wheat. The insect population increased during storage of the wheat up to 90 days, and the flour yield decreased with the storage up to 180 days. Flours from insect-infested wheat absorbed more water than did flours from control wheat. Dough stability and dough development times of infested flours decreased. Bread volume showed a progressive decline throughout the storage experiment. In conclusion, flour from insect-infested wheat exhibited changes in rheological properties such as dough stability, dough development times, water absorption, and mixing stability; bread had an offensive odor; and volume and loaf characteristics were negatively affected.     

Phenolic Compounds and Antioxidant Activity of Extruded Nixtamalized Corn Flour and Tortillas Enriched with Sorghum Bran

Sorghum bran (SB) is a good source of phenolic compounds with high antioxidant capacity that increases the antioxidant activity (AOX) of tortillas prepared with extruded nixtamalized corn flour. The objective of this research was to study the effects of bran addition (0, 5, or 10%) before (ENBESB) or after (ENAFSB) extrusion, in the features and composition of baked tortillas in terms of total phenolic compounds (TPC), AOX, color (L , a , b, hue, chroma, and E value), and tortilla firmness. It was possible to retain more than 81.8 and 89.9% of TPC and AOX, respectively, in ENBESB‐10% flour. Tortillas prepared with ENAFSB‐10% flour retained more than 92 and 76% of TPC and AOX, respectively, compared with ENBESB. However, tortillas elaborated with ENAFSB flour showed a higher firmness and lower flexibility than counterparts produced from ENBESB. The use of extrusion to produce nixtamalized corn flours and the strategy of adding the SB to the corn meal before extrusion were essential to retain TPC and AOX and, additionally, to enhance texture of tortillas.     

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.     

Modified Dough Preparation for Alveograph Analysis with Limited Flour Sample Size

Dough rheological characteristics obtained by alveograph testing, such as extensibility and resistance to extension, are important traits for determination of wheat and flour quality. A challenging issue that faces wheat breeding programs and some wheat research projects is the relatively large flour sample size of 250 g required for the standard alveograph method (AACCI Approved Method 54‐30.02). A modified dough preparation procedure for a small flour sample size was developed for the alveograph test method. A dough was prepared by mixing 80 g of flour with 60% water absorption (2.5% salt solution) for 4 min in a 100 g pin mixer; it was then sheeted and cut into three patties of defined thickness. Data generated by the modified dough preparation method were significantly correlated with the results from the approved alveograph method. The correlation coefficients (r) for each of six alveograph dough characteristics of 40 different advanced breeding lines and wheat varieties were 0.92 for P (mm H₂O), 0.73 for L (mm), 0.83 for W (10^–4 J), 0.90 for P/L, 0.90 for le (%), and 0.76 for G. The modified dough preparation was easier and more convenient than the approved method, and test time for the modified dough preparation was shorter by 20–25 min. This modified dough preparation procedure for the alveograph may be useful for wheat breeding programs as well as an alternative to the approved alveograph method for milling and baking industries and wheat quality research.     

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.     

Technological and Nutritional Properties of Flours and Tortillas from Nixtamalized and Extruded Quality Protein Maize (Zea mays L.)

Nixtamalized and extruded flours from quality protein maize (QPM, V‐537C) and tortillas made from them were evaluated for some technological and nutritional properties and compared with the commercial brand MASECA. Both QPM flours showed higher (P < 0.05) protein content, total color difference, pH, available lysine, and lower (P < 0.05) total starch content, Hunter L value, water absorption index, gelatinization enthalpy, resistant starch, and retrograded resistant starch than nixtamalized MASECA flour. Tortillas from nixtamalized and extruded QPM flours had higher contents of essential amino acids than tortillas from MASECA flour, except for leucine. Tortillas from processed QPM flours also showed higher (P < 0.05) values of the nutritional indicators calculated protein efficiency ratio (C‐PER 1.80–1.85 vs. 1.04), apparent and true in vivo protein digestibility (78.4‐79.1 vs. 75.6% and 76.4–77.4 vs. 74.2%, respectively), PER (2.30–2.43 vs. 1.31), net protein retention (NPR; 2.88–2.89 vs. 2.11), and protein digestibility corrected amino acid score (PDCAAS; 54–55 vs. 29% based on preschool children and 100 vs. 85% based on adults) than MASECA flour. The use of QPM for flour and tortilla preparation may have a positive effect on the nutritional status of people from countries where these products are widely consumed.     

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.     

Suitability of Ontario‐Grown Hard and Soft Wheat Flour Blends for Noodle Making

This study evaluated the blending of flours made from an Ontario hard red winter wheat (HWF) and an Ontario soft red winter wheat (SWF) and compared it with a commercial standard noodle flour (control) made from Canadian Western Hard Red Spring wheat to assess the impact on white salted noodle‐making performance and texture of cooked noodles. Flour characteristics, gluten aggregation, and starch pasting properties were assessed with a farinograph, GlutoPeak tester, and Rapid Visco Analyzer, respectively. The machinability of dough was evaluated with an SMS/Kieffer rig attached to a TA.XT Plus texture analyzer. Tensile and bite tests of cooked noodles were also conducted. Blending HWF with standard noodle flour decreased gluten strength and dough extensibility linearly proportional to the blend ratio, whereas a curvilinear response from blending SWF with standard noodle flour was observed. HWF demonstrated more favorable pasting properties except for lower peak viscosity for noodle making than standard noodle flour. Below a 20% blend ratio with HWF, no significant changes were seen on dough extensibility, cooking loss, tensile properties, and bite testing parameters of cooked noodles. It can be concluded that blending HWF up to a 20% level caused no significant change in the processing properties of dough and cooked noodle quality. The results also showed that the GlutoPeak tester is a sensitive tool for evaluating gluten strength in wheat flour.     

Effect of Mixing Time on Gluten Recovered by Ultracentrifugation Studied by Microscopy and Rheological Measurements

The effect of mixing time on gluten formation was studied for four commercial flour mixtures. The gluten phase was separated from dough using a nondestructive ultracentrifugation method. Small deformation dynamic rheological measurements and light and scanning electron microscopy were used. The recovered gluten was relatively pure with a small amount of starch granules embedded. The protein matrix observed by microscopy became smoother with prolonged mixing. No effect of overmixing was observed on the storage modulus (G′) of gluten for any of the flours. The amount of water in gluten increased from optimum to over‐mixing for most of the flours. Increased water content during prolonged mixing was not related to an effect on G′. The Standard flour resulted in the highest water content of gluten, which increased considerably with mixing time. The Strong flour had the lowest G′ of dough, a high G′ of gluten, and no increase in gluten water content from optimum to over‐mixing. The Durum flour did not show gluten development and breakdown similar to the other flours. The differences in gluten protein network formation during dough mixing are genetically determined and depend on the flour type.     

Relationship Between Protein Characteristics and Instant Noodle Making Quality of Wheat Flour

We investigated the relationship between the protein content and quality of wheat flours and characteristics of noodle dough and instant noodles using 14 hard and soft wheat flours with various protein contents and three commercial flours for making noodles. Protein content of wheat flours exhibited negative relationships with the optimum water absorption of noodle dough and lightness (L*) of the instant noodle dough sheet. Protein quality, as determined by SDS sedimentation volume and proportion of alcohol‐ and salt‐soluble protein of flour, also influenced optimum water absorption and yellow‐blueness (b*) of the noodle dough sheet. Wheat flours with high protein content (>13.6%) produced instant noodles with lower fat absorption, higher L*, lower b*, and firmer and more elastic texture than wheat flours with low protein content (<12.2%). L* and free lipid content of instant noodles were >76.8 and <20.8% in hard wheat flours of high SDS sedimentation volume (>36 mL) and low proportion of salt‐soluble protein (<12.5%), and <75.7 and >21.5% in soft wheat flours with low SDS sedimentation volume (<35 mL) and a high proportion of salt‐soluble protein (>15.0%). L* of instant noodles positively correlated with SDS sedimentation volume and negatively correlated with proportion of alcohol‐ and salt‐soluble protein of flour. These protein quality parameters also exhibited a significant relationship with b* of instant noodles. SDS sedimentation volume and proportion of salt‐soluble protein of flours also exhibited a significant relationship with free lipid content of instant noodles (P < 0.01 and P < 0.001, respectively). Protein quality parameters of wheat flour, as well as protein content, showed significant relationship with texture properties of cooked instant noodles.     

Effects of Oat Grain Hydrothermal Treatments on Wheat-Oat Flour Dough Properties and Breadbaking Quality

Hydrothermal treatments, which are routine in oat processing, have profound effects on oat flour dough rheological properties. The influence of roasting and steam treatments of oat grain on dough mixing and breadbaking properties was investigated when hydrothermally treated oat flour was blended with wheat flour. Roasting of oat grain (105°C, 2 hr) resulted in oat flours that were highly detrimental to wheat flour dough mixing properties and breadbaking quality. Steaming (105°C, 20 min) or a combination of roasting and steaming of oat grain significantly improved the breadbaking potential of the oat flours. The addition of oat flours increased water absorption and mixing requirements of the wheat flour dough and also decreased bread loaf volume. However, at the 10% substitution level, steamed oat flours exhibited only a gluten dilution effect on bread loaf volume when wheat starch was used as a reference. Oat flour in the breadbaking system decreased the retrogradation rate of bread crumb starch. The results indicate that adequate hydrothermal treatments of oat grain are necessary for oat flour breadbaking applications. Steamed oat flours used at a 10% level retarded bread staling without adversely affecting the loaf volume.