Influence of Fat on Expansion of Glassy Amylopectin Extrudates by Microwave Heating

The effect of solid fat (melting point 70°C) and liquid fat (melting point ‐20°C) on the microwave expansion of extruded glassy amylopectin pellets was investigated. Glassy, unexpanded amylopectin extrudates containing ≤10% fat were equilibrated at different water activity levels (a_w) and then expanded by microwave heating. Expanded products were characterized by analyzing degree of expansion, structure, and texture. For the a_w range studied, expansion increased with increasing a_w of the pellets until a maximum at a_w = 0.605 and then decreased. Completely dehydrated samples did not expand at all. This demonstrated that moisture was the driving force in the microwave expansion of the pellets. The addition of solid fat contributed greatly to expansion. The highest degree of expansion was obtained for pellets containing 6% solid fat at all a_w levels. Due to the effect on expansion, the addition of solid fat also affected the microstructure and texture of the expanded products. Concentrations of solid fat >2% resulted in expanded products with a large number of cells, uniform in size, with thin cell walls. Liquid fat addition had a negative effect on microwave expansion. The expanded products obtained from pellets that contained liquid fat had a lower expansion volume and a coarser structure.     

Effect of Xanthan Gum and CMC on the Structure and Texture of Corn Flour Pellets Expanded by Microwave Heating

Third‐generation snacks obtained by microwave expansion of glassy cereal pellets are often hard and nonuniform and need to be improved to become acceptable to the consumer. Gums such as carboxymethyl cellulose (CMC) and xanthan gum (XG) have the ability to improve the volume, structure, and texture of expanded cereal products, due to their effects on moisture retention and rheological properties. This study investigates the effect of 1% addition of CMC and XG on the structural and mechanical properties of samples obtained by microwave expansion of glassy corn pellets. Unexpanded, glassy pellets were obtained by extrusion and subsequent equilibration at a_w = 0.53 at room temperature. The equilibrated pellets were expanded by microwave heating. The addition of gums significantly improved the shape, structural and textural uniformity of the microwave‐expanded samples. These effects were attributed to the contribution of gums to the rheology and moisture sorption capacity of the matrix. It is our hypothesis that the extended hydrocolloid macromolecules interpenetrated the polymeric starch matrix and created a fine network of “holes” distributed relatively uniformly in the matrix, which served as additional nucleation sites for expansion. The conclusions of this study can be used in the design of high‐quality, fat‐free, third‐generation snacks.     

Effects of Gelatinization and Moisture Content of Extruded Starch Pellets on Morphology and Physical Properties of Microwave‐Expanded Products

Extruded pellets were prepared from normal corn starch using a corotating twin‐screw extruder (25:1 L/D ratio, 31 mm diameter screw), and then expanded by heating in a conventional microwave oven for 70 sec. The effects of gelatinization level and moisture content of the extruded pellets on the morphology and physical properties of the microwave‐expanded products such as puffing efficiency, expansion bulk volume, and bulk density were investigated. The expanded shape and air cell structure differed according to the degree of gelatinization of the pellets. Maximum puffing efficiency and expansion volume with the pellets containing 11% moisture were achieved at 52% gelatinization. For this level of gelatinization, starch was extruded at 90°C barrel temperature. In addition, the moisture content of the pellets critically affected the expansion behavior. The maximum puffing efficiency and expansion volume were achieved in a moisture range of 10~13%. For optimum product shape and uniform air cell distribution, the pellets should undergo sudden release of the superheated vapor during the microwave‐heating. The expansion by microwave‐heating was optimized at ≈50% gelatinization.     

Preparation of High‐Quality Protein‐Based Extruded Pellets Expanded by Microwave Oven

The aim of this work was to study the effects of extrusion barrel temperature (75–140°C) and feed moisture (16–30%) on the production of third‐generation snacks expanded by microwave heating. A blend of potato starch (50%), quality protein maize (QPM) (35%), and soybean meal (SM) (15%) was used in the preparation of the snacks. A laboratory single extruder with a 1.5 × 20.0 × 100 mm die‐nozzle and a central composite routable experimental design were used. Expansion index (EI) and bulk density (BD) were measured in expanded pellets, viscosity at 83°C (V₈₃), thermal properties, and relative crystallinity were measured in extruded pellets. EI increased and BD decreased when the barrel temperature was increased, while the feed moisture effect was not significant. V₈₃ increased when feed moisture increased. Extrusion modified the crystalline structures of the pellets and the X‐ray data suggests the formation of new structures, probably due to the development of amylose‐lipid complexes. The maximum expansion of pellets was found at barrel temperatures of 123–140°C, and feed moisture of 24.5–30%. It is possible to obtain a functional third‐generation snack with good expansion characteristics using a microwave oven, and this snack has health benefits due to the addition of QPM and SM.     

Effect of Single‐Screw Extruder Die Temperature,Amount of Distillers' Dried Grains With Solubles (DDGS), and Initial Moisture Content on Extrudates

Corn distillers' dried grains with solubles (DDGS) was extruded with corn meal in a pilot plant single‐screw extruder at different extruder die temperatures (100, 120, and 150°C), levels of DDGS (0, 10, 20, and 30%) and initial moisture contents (11, 15, and 20% wb). In general, there was a decrease in water absorption index (WAI), water solubility index (WSI), radial expansion, and L* value with an increase in DDGS level, whereas a* value and bulk density increased. Increase in extruder die temperature resulted in an increase in WSI and WAI but a decrease in L* and bulk density. Peak load was highest at 30% DDGS as compared with 0, 10, and 20% DDGS extrudates. Die temperature of 120°C and initial moisture content of 20% resulted in least peak load. The a* value remained unaffected by changes in extruder die temperature. Radial expansion was highest at extruder die temperature of 120°C. Maximum WAI, WSI, radial expansion, and L* value were obtained at 15% initial moisture content. An increase in initial moisture content, in general, decreased L* value and bulk density but increased a* value of extrudates.     

Moisture Redistribution and Phase Transitions During Bread Staling

Standard white breads were stored with or without crust at 25°C in hermetic pouches. During two weeks of storage, the crumb moisture content and water activity (a_w) decreased significantly when stored with crust. When stored without crust, moisture content and a_w remained relatively unchanged. The causes of the initial firming of both breads over zero to seven days were not conclusive. But when stored beyond seven days, bread stored with crust was significantly firmer in texture and higher in amylopectin recrystallization than bread stored without crust. Moisture redistribution from crumb to crust played a significant role. This was accompanied by a decrease in freezable water in the bread crumb stored with crust. This loss in freezable water coincided with changes in the thermomechanical profile only in the case of sample stored with crust intact (and with a significant total and freezable water loss). Bread crumb stored without crust did not change in total and freezable water and showed less change in thermomechanical transitions. The transition occurring at ≈60°C (T₂) correlated with amylopectin recrystallization but it could also have been caused by moisture loss during the analysis. Moisture migration from crumb to crust greatly reduced the total and freezable water in the crumb region, resulting in a significant reduction in the magnitude of the mechanical transition at ≈0°C (T₁) as well as an increase in the storage modulus.     

Development and Characterization of Extruded Pellets of Whole Potato (Solanum tuberosum L.) Flour Expanded by Microwave Heating

In various Latin American countries, large volumes of potato are classified as unsuitable for use as food and destined for use as feed. This raw material has a high starch and fiber content that could be used in the production of different kinds of food. The objective of this research was the preparation and characterization of extruded whole potato pellets expanded by microwave heating. A 3³ central composite routable experimental design and response surface methodology were used. The barrel temperature (BT, 93–127°C), feed moisture (FM, 19–29%), and corn starch concentration (CS, 3–37%) in the blends were evaluated. CS was the most important variable affecting the functional properties of the expanded pellets. Adding CS to the blends increased the expansion index and viscosity and improved luminosity, decreasing the apparent density and breaking force of the products. Low BT and especially high FM increased the luminosity of the expanded pellets. Increasing FM content increased the viscosity of the expanded pellets. The best functional characteristics for the expanded pellets were obtained using a blend of 63% potato flour and 37% CS, extruded at 110°C BT with 24% FM content. Nonfood-grade whole potato flour showed good potential for use in the production of expanded pellets with acceptable functional properties.     

Measuring and Modeling Grain Sorption Equilibria of Amaranth Grains

Water activity (a_w)of Amaranthus cruentus were measured at 35, 45, and 65°C at different moisture contents by means of an electronic water activity meter. Experimental curves were fitted to one three-parameter equation (GAB equation). The equilibrium values and temperature shifts were modeled with a three-parameter equation in the approximate a_w range of 0.03–0.88. An analytical expression to calculate the isosteric heat of sorption and its moisture content dependence was used, and the results were compared with the isosteric heat calculated from the experimental equilibrium data by means of the Clausius-Clapeyron equation.     

Characteristics of Vegetable‐Based Twin‐Screw Extruded Yellow Perch (Perca flavescens) Diets Containing Fermented High‐Protein Soybean Meal and Graded Levels of Distillers Dried Grains with Solubles

A twin‐screw extrusion study was performed in replicated trials to produce vegetable‐based feeds for juvenile yellow perch. Two isocaloric (3.06 kcal/g) experimental diets were balanced to contain 20 and 40% distillers dried grains with solubles (DDGS) and a constant amount (20%) of fermented high‐protein soybean meal (PepSoyGen) as the fishmeal protein replacers; crude protein content was targeted at 40%. A fishmeal‐based diet was used as a control. Extrusion conditions included conditioner steam (0.11–0.16 kg/min), extruder water (0.11–0.19 kg/min), and screw speed (230–300 rpm). Increasing DDGS from 0 to 40% led to a considerable rise in bulk density, lightness L*), yellowness (b*), and unit density but to decreases in water activity (a_w) and expansion ratio by 12.6, 14.4, 23, 21, 31, and 13%, respectively. The lowest unit density of 791.6 kg/m³ and highest bulk density of 654.5 kg/m³ were achieved with diets containing 20 and 40% DDGS, respectively; changes in DDGS content did not affect extrudate moisture, absorption index, or thermal properties. Raising DDGS from 0 to 40% resulted in an increase in water solubility and redness (a*) by 13.4 and 35%, respectively. All extrudates had high durability (>98%), and low a_w of less than 0.5. Overall, this study yielded viable feeds for yellow perch.     

Effects of Waxy Rice Moisture Content and Rate of CO2 Injection on Characteristics of Extruded Pellets and Vacuum‐Puffed Yukwa (a Korean Traditional Snack)

Extrusion with CO₂ injection was developed to simplify the process of producing vacuum‐puffed yukwa (rice snacks). The effects of feed moisture content and CO₂ injection on the characteristics of extruded pellets (maximum viscosity and degree of gelatinization) and vacuum‐puffed yukwa (expansion ratio, bulk density, hardness, and color) were investigated. Higher feed moisture increased the size of vacuum‐puffed yukwa and the degree of gelatinization, whereas the maximum viscosity decreased. Maximum viscosity and gelatinization degree of extruded pellets were highly correlated with expansion ratio, bulk density, hardness, and color values of vacuum‐puffed yukwa. Increasing feed moisture content significantly increased expansion ratio but decreased bulk density and hardness. CO₂ injection decreased bulk density and hardness of vacuum‐puffed yukwa.     

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

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

Single‐Screw Extrusion Processing of Distillers Dried Grains with Solubles (DDGS)‐Based Yellow Perch (Perca flavescens) Feeds

This study was conducted to investigate the production of balanced diets for juvenile yellow perch (Perca flavescens) feeds. Six isocaloric (≈3.21 kcal/g), isonitrogenous (30.1 ± 0.4% db) ingredient blends were formulated with 0, 10, 20, 30, 40, and 50% distillers dried grains with solubles (DDGS), and appropriate amounts of soybean meal, fish meal, vitamins, and minerals. Extrusion cooking was performed using a laboratory‐scale single‐screw extruder at a constant barrel temperature profile of 40–90–100°C, and a constant screw speed of 230 rpm (24.1 rad/sec). The mass flow rate was determined during processing; it generally increased with progressively higher DDGS content. Additionally, moisture content, water activity, unit density, expansion ratio, compressive strength, compressive modulus, pellet durability index, water stability, and color were extensively analyzed to quantify the effects of DDGS content on the physical properties of the resulting extrudates. Significant differences (P < 0.05) between blends were observed for color and water activity for both the raw material and extrudates, respectively, and for the unit density of the extrudates. There were significant changes in brightness (L), redness (a), and yellowness (b) among the final products when increasing the DDGS content of the blends. Expansion ratio and compressive strength of the extrudates were low. On the other hand, all blends showed high pellet durability (PDI ≥ 96.18%). Overall, it was ascertained that DDGS could be successfully included at rates of <50%, and that each of the ingredient blends resulted in viable, high quality extrudates.     

Differential Scanning Calorimetry Glass Transition Temperatures of White Bread and Mold Growth in the Putative Glassy State

Differential scanning calorimetry (DSC) was used to determine the onset and end temperatures of the glass transition (T_g) for white bread equilibrated between 53 and 84% rh. Calorimetric T_g end values were ≈20°C higher than onset values, indicating that it is probably more correct to refer to a “glass transition range” rather than a glass transition temperature. Slices of white bread inoculated with a mixture of xerophilic molds were equilibrated to 75% rh (equilibrium moisture content of 14.5 g of water/100 g of dry material) and stored at 26°C. In a parallel experiment, some of the equilibrated bread samples were stored without mold inoculation and subjected to spontaneous contamination from the immediate surroundings. As suggested by measured T_g, bread stored at 75% rh and 26°C appeared to be glassy. After storage, samples of bread (inoculated or not) were spoiled by xerophilic molds, suggesting that T_g, as measured by DSC, cannot be considered as an absolute threshold for mold growth inhibition.     

Nonenzymatic Browning During Storage of Infant Cereals

The browning indicators furosine and color were determined in infant cereals and infant cereals containing powdered milk to evaluate the utility of these parameters for monitoring storage. Studies were made on seven infant cereal samples including both gluten and gluten‐free products. Samples were stored under laboratory conditions at 28°C for four or 16 weeks; or under modified water activity conditions at 25°C or 55°C for one, two, three, or four weeks; or under industrial conditions in air or nitrogen atmospheres at 32°C or 55°C for one, three, six, or 12 months. Furosine levels increased during the storage of infant cereals containing powdered milk under all time, temperature, and water activity (a_w) conditions assayed, except drastic conditions (55°C, a_w = 0.65). Color values increased in infant cereals with gluten (7‐cereal and 8‐cereal samples), regardless of milk content, when they were stored under drastic conditions (55°C or 25°C with normal or modified water activity). However, the gluten‐free infant cereals (rice‐corn and rice‐corn‐soy samples) that have a characteristic yellow color showed no increase in color during storage. The extent of the Maillard reaction was greatest in the infant cereals that included milk in their formulation.     

Influence of moisture on the vital activity of actinomycetes in a cultivated low-moor peat soil

It was found that the actinomycetal complex of a cultivated low-moor peat soil is characterized by a high population density and diversity of actinomycetes; representatives of eleven genera were isolated from this soil: Streptomyces, Micromonospora, Actinomadura, Saccharopolyspora, Microbispora, Microtetraspora, Streptosporangium, Nocardioides, Saccharomonospora, Kibdelosporangium, and Thermomonospora. Some genera were isolated from the soil under all the studied levels of soil moisture. The so-called rare (rarely occurring) genera (Saccharomonospora, Kibdelosporangium, and Thermomonospora) were isolated upon the low level of soil moisture, which ensured an absence of competition from the more abundant actinomycetes. Spores of all the studied actinomycetes could germinate under the low moisture level (a _w = 0.67). The level of moisture a _w = 0.98 was found to be optimal for the development of the actinomycetes. The complete cycle of the development of all the actinomycetes up to spore formation occurring was only observed under the high moisture level (a _w = 0.98).     

Effects of Production by Microwave Heating After Conventional Baking on Moisture Gradient and Product Quality of Biscuits (Cookies)

After conventional (forced-convection heating) baking at 240°C for 4 min, biscuits (cookies) were baked further in a microwave oven at medium and high settings (617.3 and 745.5 W, respectively) to study the effects of microwave baking on the moisture gradient and overall quality of the cookies. Microwave baking significantly (P < 0.05) reduced the moisture gradient and total moisture content of the cookies. Initially, a complete factorial design at baking times of 15, 20, 30, and 40 sec with microwave ovens at high and medium power settings was used to evaluate the moisture gradient and total cookie moisture content. Applying high and medium microwave settings for 30 or 40 sec, respectively, avoided cracking, although the products were slightly darker. Treatment at a high power setting for 20 sec resulted in a moisture gradient of 1.11%/cm and 2.8% cracking. Gradients >1.5%/cm produced significant levels of cracking. Cookies postbaked at a medium microwave power setting for 29 sec produced the same moisture gradient as a high microwave power setting for 23 sec, which was significantly (P < 0.05) lower than the control (cookies baked using the traditional process). The cookies were softer and the color did not differ significantly from that of the control. The expansion ratio of the control sample (11.3) was significantly higher than the combined process sample (10.7), showing a shrinkage effect attributed to the microwave treatment. The removal of the residual moisture during microwaving also increased product weight losses (from 0.912 to 0.956 g).     

Impact of clod (aggregate) size on evaporation rate and soil moisture profile during the drying process

Large clods (centimetres in size) can be formed by tillage in clayey paddy fields where upland crops are planted. These clods cause early water depletion near the soil surface, which decreases crop germination and emergence rates. Because of the difficulty in reducing clod size, desiccation damage to seeds can be avoided by adjusting the seeding depth based on the clod size-dependent soil moisture profile. This study aimed to clarify the effect of clod size on (1) the evaporation rate (E) and soil moisture profile and (2) the mobility of soil water during the drying process. Evaporation experiments were conducted in an air-conditioned greenhouse with natural light using cylindrical columns filled with artificially made clods 3 (L columns) and 1 cm (S columns) in diameter. We measured E, potential evaporation rate (PE), and total soil moisture content (w_tot) throughout the experiment and the soil moisture profiles at the end of the experiment. The water diffusivity (D_w) and apparent vapour diffusion coefficient (d_vap) were calculated as the mobility of soil water and water vapour, respectively. We found that w_tot was lower in the L column than in the S column, although not at the onset of the experiment. At the end of the experiment, the soil moisture content was lower in the L column than in the S column throughout the soil layer. In contrast, E/PE was higher in the L column than in the S column throughout the experiment and even at the same w_tot. Regarding mobility, D_w was slightly greater in the L column than in the S column in the soil moisture content range, where vapour movement could be greater than liquid water movement. In addition, the ratio of d_vap to the diffusion coefficient of water vapour in soil was higher than unity in both columns and was 2.4–3.2 times higher in the L column than in the S column. In summary, larger clods caused a higher evaporation rate and lower soil moisture content, owing to the increased enhancement of water vapour movement probably induced by wind.     

Effects of Processing Conditions and Sorghum Cultivar on Alkaline-Processed Snacks

Sorghum (Sorghum bicolor (L.) Moench) grain was boiled or autoclaved in alkali, washed, drained, and dried into shelf-stable half-products (pellets). The pellets were deep-fat fried to produce a crunchy snack product. Effects of cooking time, drying method (pellet moisture content), and sorghum cultivar on unfried and fried pellets were evaluated. Increasing the alkaline cooking time from 30 to 60 min decreased the yield of the pellets from 96 to 84% (on a dry weight basis). Cooked sorghum dried at room temperature (24°C) for 18 hr, followed by oven-drying at 50°C for an additional 18 hr, produced pellets with a low moisture content (≤5%), that required a higher frying temperature (≥220°C). However, cooked sorghum dried at room temperature for 18 hr followed by oven-drying at 50°C for 5 hr produced pellets with 9% moisture and a lighterdensity highly acceptable product when fried at 220°C. Fat content of fried pellets averaged 18%. The optimum method for producing a light, crunchy, fried product was cooking for 60 min, drying to 9% moisture, and frying at 220°C. ATx631*Tx436, the hardest endosperm-texture sorghum used in the study, had the highest unfried and fried pellet yields. Dorado, an intermediate-to-soft endosperm-texture sorghum, and ATx Arg-1*Tx2907, a waxy sorghum, had lower yields. The fried pellets produced from Dorado and waxy sorghum (ATxArg-1*Tx2907) were more expanded than those produced from ATx631*Tx436.     

Effect of Sucrose on Glass Transition,Gelatinization, and Retrogradation of Wheat Starch

Differential scanning calorimetry (DSC) was used to study the effect of sucrose on wheat starch glass transition, gelatinization, and retrogradation. As the ratio of sucrose to starch increased from 0.25:1 to 1:1, the glass transition temperature (T_g, T_g′) and ice melting enthalpy (ΔH_ice) of wheat starch‐sucrose mixtures (with total moistures of 40–60%) were decreased to a range of −7 to −20°C and increased to a range of 29.4 to 413.4 J/g of starch, respectively, in comparison with wheat starch with no sucrose. The T_g′ of the wheat starch‐sucrose mixtures was sensitive to the amount of added sucrose, and detection was possible only under conditions of excess total moisture of >40%. The peak temperature (T_m) and enthalpy value (ΔH_G) for gelatinization of starch‐sucrose systems within the total moisture range of 40–60% were increased with increasing sucrose and were greater at lower total moisture levels. The T_g′ of the starch‐sucrose system increased during storage. In particular, the significant shift in T_g′ ranged between 15 and 18°C for a 1:1 starch‐sucrose system (total moisture 50%) after one week of storage at various temperatures (4, 32, and 40°C). At 40% total moisture, samples with sucrose stored at 4, 32, and 40°C for four weeks had higher retrogradation enthalpy (ΔH) values than a sample with no sucrose. At 50 and 60% total moisture, there were small increases in ΔH values at storage temperature of 4°C, whereas recrystallization of samples with sucrose stored at 32 and 40°C decreased. The peak temperature (T_p), peak width (δT), and enthalpy (ΔH) for the retrogradation endotherm of wheat starch‐sucrose systems (1:0.25, 1:0.5, and 1:1) at the same total moisture and storage temperature showed notable differences with the ratio of added sucrose. In addition, T_p increased at the higher storage temperature, while δT increased at the lower storage temperature. This suggests that the recrystallization of the wheat starch‐sucrose system at various storage temperatures can be interpreted in terms of δT and T_p.     

Heat expanded starch-based compositions

A heat expansion process similar to that used for expanded bead polystyrene was used to expand starch-based compositions. Foam beads made by solvent extraction had the appearance of polystyrene beads but did not expand when heated due to an open-cell structure. Nonporous beads, pellets, or particles were made by extrusion or by drying and milling cooked starch slurries. The samples expanded into a low-density foam by heating 190-210 degrees C for more than 20 s at ambient pressures. Formulations containing starch (50-85%), sorbitol (5-15%), glycerol (4-12%), ethylene vinyl alcohol (EVAL, 5-15%), and water (10-20%) were studied. The bulk density was negatively correlated to sorbitol, glycerol, and water content. Increasing the EVAL content increased the bulk density, especially at concentrations higher than 15%. Poly(vinyl alcohol) (PVAL) increased the bulk density more than EVAL. The bulk density was lowest in samples made of wheat and potato starch as compared to corn starch. The expansion temperature for the starch pellets decreased more than 20 degrees C as the moisture content was increased from 10 to 25%. The addition of EVAL in the formulations decreased the equilibrium moisture content of the foam and reduced the water absorption during a 1 h soaking period.