Stability of Native Folate and Added Folic Acid in Micronutrient‐Fortified Corn Masa and Tortillas

Degradation of added folic acid and native folates in micronutrient‐fortified corn masa and tortillas was evaluated using masa prepared from either nixtamalized corn flour or fresh nixtamal. Variations in masa pH, masa holding time at an elevated temperature, and iron source failed to show significant differences in folate loss in corn flour masa prepared in the laboratory. Masa was subsequently prepared from fresh nixtamal in a commercial mill in Mexico, and fortified with one of two different micronutrient premixes containing iron, zinc, B‐vitamins, and either unencapsulated or lipid‐encapsulated folic acid. Folate loss in commercial masa increased significantly with prebake masa holding time for both premixes. Unencapsulated folic acid showed a 73% loss after 4 hr of holding, compared to 60% loss for encapsulated. The difference was statistically significant, indicating a protective effect from the lipid coating. No significant differences in folate levels were found between prebake masa and baked tortillas. Holding baked tortillas for up to 12 hr also had no effect on folate levels. Native folate showed no significant losses throughout the process. Results from the commercial tortilla mill indicate that most of the loss in added folic acid occurs during prebake holding of masa, possibly from microbial degradation.     

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.     

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.     

Commercial Evaluation of a Continuous Micronutrient Fortification Process for Nixtamal Tortillas

The corn tortilla plays an integral role in the Mexican diet and is an ideal vehicle for micronutrient fortification. Approximately 60% of corn tortillas in Mexico are produced from nixtamal, with the remainder prepared from masa flour. A process for continuous fortification of nixtamal tortillas was evaluated in two commercial mills in Mexico. A commercial powder dosifier was used to add micronutrient premix containing iron, zinc, folic acid, niacin, riboflavin, and thiamin to nixtamal (1 g/kg) as it was milled. After training and preliminary sampling, mills produced fortified tortillas unassisted for four weeks. Masa flow rates over a four‐day period were 10–12 kg/min in both plants. Premix flow from the dosifier showed good stability, with an average coefficient of variation of 1.6%. Initial results indicated consistency in the fortification process, with significantly increased variation during the four‐week production period. Fortified tortillas had significantly higher levels of all nutrients tested. Micronutrient losses were <11% in all cases except folic acid, which showed an 80% loss. Despite processing losses, fortification resulted in a nearly fivefold increase in folic acid compared with control tortillas. The new fortification process is technically viable and was well received by millers.     

HPLC Determination of Stability and Distribution of Added Folic Acid and Some Endogenous Folates During Breadmaking

Bread flour was spiked with folic acid (1.40 mg/lb or 3.08 μg/g of flour) and processed into bread by the sponge and dough method. Changes that occurred to added folic acid and endogenous folate contents through different processing stages, including sponge formation, proofing, and baking, were assessed by reversed‐phase ion‐pair HPLC combined with UV and fluorometric detection. Sample extraction required α‐amylase and rat plasma deconjugase digestion, and sample preparation required purification by solid‐phase extraction. Added folic acid was measured by monitoring UV absorption at 280 nm. Four selected forms of endogenous folates including tetrahydrofolate (THF), 5‐formyl‐THF, 10‐formylfolate, and 5‐methyl‐THF were identified and quantified throughout the bread processing using a fluorescence excitation wavelength of 290 nm and emission wavelength of 350 or 450 nm. Data indicate a relatively good stability of added folic acid and native folates to the baking process, and increased endogenous folate contents in dough and bread as compared with the flour from which they were made.     

Analytical Techniques for Understanding Nixtamalized Corn Flour: Particle Size and Functionality Relationships in a Masa Flour Sample

Instant masa flour finds extensive use in the food industry for making tortillas, taco shells, tamales, corn chips, and tortilla chips, and as an ingredient in extruded snacks. Due to lack of standard techniques for measuring masa functionality, processors and end‐users use masa flour particle‐size distribution and rheological characteristics in an attempt to predict its end use. In this study, a commercial masa flour sample was characterized by fractionating on the basis of particle size. Physicochemical and functional properties of masa flour fractions were investigated to establish structure‐composition and functionality relationships. It was observed that Rapid Visco Analyser (RVA) pasting profiles of flour fractions and textural properties of dough prepared on rehydration were related to particle size, yet, upon regrinding, RVA profiles did not change as markedly as expected. Differences in RVA measurements of the sized fractions could not be explained on the basis of hydration rate or total starch content. It was concluded that masa dough textural and RVA characteristics may be influenced by the status of starch polymer structures formed during nixtamalization.     

Association of Glutenin Subunit Composition and Dough Rheological Characteristics with Cookie Baking Properties of Soft Wheat Cultivars

The effect of flour type and dough rheology on cookie development during baking was investigated using seven different soft winter wheat cultivars. Electrophoresis was used to determine the hydrolyzing effects of a commercial protease enzyme on gluten protein and to evaluate the relationships between protein composition and baking characteristics. The SDS‐PAGE technique differentiated flour cultivars based on the glutenin subunits pattern. Electrophoresis result showed that the protease degraded the glutenin subunits of flour gluten. Extensional viscosities of cookie dough at all three crosshead speeds were able to discriminate flour cultivar and correlated strongly and negatively to baking performance (P < 0.0001). The cookie doughs exhibited extensional strain hardening behavior and those values significantly correlated to baking characteristics. Of all rheological measurements calculated, dough consistency index exhibited the strongest correlation coefficient with baking parameters. The degradation effects of the protease enzyme resulted in more pronounced improvements on baking characteristics compared with dough rheological properties. Stepwise multiple regression showed that the dough consistency index, the presence or absence of the fourth (44 kDa) subunit in LMW‐GS and the fifth subunit (71 kDa) subunit in HMW‐GS were predominant parameters in predicting cookie baking properties.     

Use of Tannic Acid as Dough Oxidizing and Vitamin C Protective Agent

Trials with tannic acid in three concentrations (0.1, 0.2, and 0.3%) in a wheat flour dough were run to test its property to preserve the ascorbic acid degradation during baking and its performance in the dough viscoelasticity measured by its extensigraphic properties. The addition of tannic acid to the dough in the cited concentrations increased its resistance to extension (RE) and consequently reduced its extensibility (E) in the same way that ascorbic acid performed but using concentrations 10× smaller. In a dough containing ascorbic acid 0.02% and tannic acid 0.3%, the ascorbic acid retention after 10 days of storage was 34.8%, which represents 154% of the recommended daily intake of vitamin C by FAO/WHO (2002) for an adult (19–65 years old). The addition of tannic acid to the dough also increased the bread specific volume.     

The Rheo Extrusion Meter,a New Device for Measuring Wheat Flour Baking Absorption and Dough Consistency: Principle and Applications

The Rheo Extrusion Meter (REM) measures the time for vertical upward extrusion of wheat flour dough (subsequently referred to as extrusion time, ET) as a measure of its consistency. ET evidently increases with dough consistency. ETs are highly reproducible and sensitive to differences in dough moisture content. A single REM analysis takes 20 min, and the measured ET can be converted into the correct baking absorption at a given temperature. The heights of the extruded dough pieces are negatively correlated with straight‐dough bread loaf specific volume, both when comparing different flour samples and when adjusting moisture content of dough prepared from a given flour sample. The REM also allows determination of the consistency of complex wheat flour based systems and the impact of vital wheat gluten or ascorbic acid thereupon. Furthermore, in contrast to the farinograph, it detects the impact of endoxylanases hydrolyzing water‐extractable arabinoxylan on dough consistency.     

Polyphenolics and Antioxidant Capacity of White and Blue Corns Processed into Tortillas and Chips

White and blue corns of Mexican and American origins were lime-cooked to obtain nixtamals with optimal moisture (48–50%) for tortillas and chips. Blue kernels had less bulk density, softer endosperm and, consequently, required less cooking time than the white kernels. The optimum cooking regime for the white kernels was 100°C for 20 min, while the optimum for both pigmented genotypes was 90°C for 0 min (until the lime-cooking solution reached 90°C). Doughs, tortillas, and chips were characterized by total soluble phenolics (TSP), anthocyanins (ACN), and antioxidant capacity (AOX). A dough acidification procedure using fumaric acid (pH 5.2) was assessed as a means to improve TSP, ACN, and AOX retention. The Mexican blue corn had higher AOX (16%) than the American blue genotype, although the latter had a threefold higher TSP content (12.1 g/kg, dwb). Mexican and American blue corns had higher AOX capacity (29.6 and 25.6 μM trolox equivalents [TE]/g dwb), respectively, than the white corn (17.4 μM TE/g). White corns did not have detectable amounts of ACN, while blue Mexican and American kernels contained 342 and 261 mg/kg. Lime cooking had the greatest negative impact on the stability of TSP, ACN, and AOX. However, the acidification reduced ACN, TSP, and AOX losses by 8–23, 3–14, and 4–15%, respectively. Similar ACN losses were observed for both types of blue kernels when processed into nixtamal/dough (47%); however, ACN losses in tortillas and chips manufactured from the American blue genotype were higher (63 and 81%, respectively) than those of Mexican blue corn products (54 and 75%). ACN losses were highly correlated to TSP (r = 0.91) and AOX capacity losses (r = 0.94).     

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.     

Influence of Milk,Corn Starch,and Baking Conditions on the Starch Digestibility,Gelatinization, and Fracture Stress of Biscuits

Dough for nontraditional semisweet biscuits—prepared with wheat flour or replacing part of the wheat flour with corn starch, with or without skim milk—was baked at two oven temperatures, 120 or 170°C, until reaching moisture content and water activity lower than 6% and 0.5, respectively. Assays of fracture stress, differential scanning calorimetry, X‐ray diffraction, and starch digestibility were performed. Results showed that biscuits containing milk had the highest fracture stress, and biscuits baked at low temperature were harder than biscuits baked at high temperature. The degree of starch gelatinization during baking was higher when dough was baked at 170°C, compared with dough baked at 120°C. The decrease in gelatinization coincides with the decrease in the height and surface of peaks at 15 and 23° in the X‐ray diffraction patterns. Milk and corn starch did not affect the starch digestibility of biscuits, but biscuits baked at 170°C presented lower fracture stress and higher starch digestibility than biscuits baked at 120°C.     

Two Metal Ions Improve Brightness in Wheat-Dough Products and Affect Aqueous Dispersion of Gluten

Zinc and aluminum ions at 0.05% of wheat flour, dry basis (7.4 and 18.5 mmol/100 g, respectively), improved the brightness of raw and dried spaghetti and salt and alkaline noodles. They also retarded bacteria and yeast and mold growth in salt noodles held at 25°C for two days as determined by total plate counts. Neither metal ion caused a change in noodle cooking quality, but they imparted a slight aftertaste in cooked noodles. Wheat flour dough mixed with 0.05% zinc or 0.025% aluminum ion (fwb), when kneaded in aqueous 0.1% calcium chloride, gave gluten with increased brightness. Zinc and aluminum ions appear to complex with enzymic browning chromophores in wheat dough and gluten and change their spectral properties. Zinc and aluminum ions affected the dispersion of gluten in water at pH ~5.0 and facilitated its spray-drying, but they were not detrimental to baking quality. Citric and tartaric acids at 5 mmol/100 g of gluten (db) gave wet gluten with pH ~4.5, which improved its brightness and water dispersibility.     

Quality and Fortificant Retention of Rice Noodles as Affected by Flour Particle Size

Rice noodles, which are widely consumed noodles in Southeast Asia, were evaluated as a potential carrier for fortificants such as vitamin A, folic acid, and iron. Because flour particle size was found to affect the noodle properties, this study was conducted to investigate the effect of five different particle sizes (≤63, 80, 100, 125, and 140 µm) of dry‐milled rice flour on the cooking quality, microstructure, texture, and sensory characteristics of the rice noodles. The retention of fortificant in the noodles at every stage of processing as affected by the flour particle size was also determined. It was found that the rice noodles produced from flour with the smallest particle size studied (≤63 µm) had the best quality and were the most liked by the consumers. In addition, the noodles had the most compact and regular structure, which could be attributed to having the most severely gelatinized starch. This starch would have caused the least leaching of the fortificant into the surrounding water during the boiling stage of the rice noodle processing. Retention of iron in the cooked fortified rice noodles prepared from flour with the smallest particle size was high at around 87%, whereas that of vitamin A and folic acid were below 15%. Because the losses of the fortificant from the rice noodles were mostly owing to the boiling process, further improvements of the rice noodle processing conditions are required for reduction of the vitamin losses.     

Assessing Degree of Cook During Corn Nixtamalization: Impact of Processing Variables

Nixtamalization involves cooking and steeping corn in a lime solution, washing the corn (nixtamal), and stone grinding nixtamal to form a corn dough or masa. Masa is used to produce nixtamalized products (corn tortillas, tortilla chips, corn chips, taco shells, etc.) by forming and baking or deepfat frying. The degree of corn kernel cook determines the quality and texture of masa. Response surface methodology (RSM) was used as an experimental design to study the impact of process variables (cook temperature, cook time, initial steep temperature, and steep time) on the degree of cook measured using a Rapid Visco Analyser (RVA) and differential scanning calorimetry (DSC). RSM data exhibited significant (P < 0.005), although not predictive, linear models for RVA peak viscosity (r² = 0.63), setback (r² = 0.61), final viscosity (r² = 0.61), and peak time (r² = 0.57), indicating a dependence of these parameters on nixtamalization conditions. Peak viscosity, setback, and final viscosity increased linearly with steep time. DSC enthalpy (r² = 0.83) and peak temperature (r² = 0.89) of freezedried masa also exhibited significant (P < 0.0001) linear regression models with processing variables. DSC enthalpy increased with an increase in steep time, suggesting that starch is annealed during steeping. This study demonstrated that fundamental starch properties were altered on extended steeping during nixtamalization.     

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.     

Contribution of Sourdough Lactobacilli,Yeast, and Cereal Enzymes to the Generation of Amino Acids in Dough Relevant for Bread Flavor

The amino acid release was determined in wheat doughs supplied with salt, acid, dithiothreitol, or starter cultures to evaluate the relevance of the amino acid concentration on bread flavor. Wheat flour proteinases almost linearly released amino acids and the highest activity of wheat flour proteinases was found in acidified and reduced doughs. The effects of starter cultures on amino acid concentrations depended on their composition. Yeasts exhibited a high demand for amino acids, however, the total amino acid concentrations were not markedly affected by lactic acid bacteria. The individual amino acid contents were determined by the pH during fermentation and microbial metabolism. The formation of proline was favored by values higher than pH 5.5, whereas release of phenylalanine, leucine and cysteine mainly occurred at lower pH. Ornithine was found only in doughs fermented with Lactobacillus pontis. To determine effects of the amino acid concentration on bread aroma, fermented doughs were evaluated in baking experiments. An increased intensity of bread flavor was obtained by preferments prepared with lactic acid bacteria. The roasty note of wheat bread crust could be markedly enhanced by L. pontis. This results support the assumption that flavor of wheat bread is enhanced by increasing the concentration of free amino acids and especially ornithine in dough.     

Nixtamalized Instant Flour from Corn (Zea mays L.) Meal: Optimization of Nixtamalization Conditions

The present investigation provides a new method for the nixtamalization process wherein corn endosperm fractions (corn meal) are treated in an alkaline solution that yields quality masa or instant masa flour like traditional nixtamalization process (alkaline cooking of corn with lime). The objective of this work was to determine the best combination of nixtamalization process variables for producing nixtamalized instant flour (NIF) from corn meal. Nixtamalization conditions were selected from factorial combinations of process variables including nixtamalization time (NT 8–22 min) and cooking temperature (CT 78–88°C). A central composite rotable experimental design was chosen. Lime concentration was 1% (10 g of Ca(OH)₂/L of water) and ratio of corn meal to cooking medium was 1:4. At the end of each cooking, each treatment was steeped for 5 hr at room temperature (25°C). Nixtamalized corn meal was dried (55°C/12 hr) and milled to pass through 80 U.S. mesh to obtain NIF. Response surface methodology (RSM) was applied as an optimization technique over four response variables: masa firmness (MF), masa adhesiveness (MA), tortilla cutting force (CF), and tortilla tensile strength (TS). Predictive models for response variables were developed as a function of process variables. Conventional graphic methods were applied to obtain response variable values similar to the control (MASECA). Contour plots of each response variable applied superposition surface methodology to obtain a contour plot for observation and for selecting the best combination of nixtamalization time (NT 15 min) and cooking temperature (CT 83°C) for producing an optimized NIF from corn meal. Values of MF, MA, CF, and TS obtained from the predictive models were compared with those derived from experimental tests; a close agreement (coefficient of variance < 10%) between both values was observed.     

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 Physical States of Nonpolar Lipids on Rheology,Ultracentrifugation, and Microstructure of Wheat Flour Dough

In the previous study, we investigated effect of physical state of nonpolar lipids of gluten‐starch model dough. This experiment examined a real wheat flour dough system to assess the role of fat crystals in the breadmaking processes. These experiments were performed with a baking test and an investigation of wheat flour dough through rheological measurements (both large and small deformations), scanning electron microscopy, and ultracentrifugation. As a result, we found that the added oil was absorbed in the gluten structure, causing the aggregation of the gluten, which gave rise to more elastic behavior. In contrast, solid fat seemed to be distributed uniformly between the starch granules in the dough, reducing the friction between the starch granules and facilitating thin gluten gel layers. These properties lead to the lower G′ value and the increased viscous behavior, which yields an increase in loaf volume. In addition, the supposed mechanism behind the large loaf volume described in the previous study was that fat provides a uniform distribution of the dough components, and that the dough can thus expand easily, resulting in a larger loaf volume, which was supported in the wheat flour dough system. In conclusion, we found that thin, expandable gluten films and the uniform dispersion of gluten and starch granules in the dough are prerequisites for attaining better baking performance.