Extrusion Processing of Rice‐Based Breakfast Cereals Enhanced with Tocopherol from a Chinese Medical Plant

Brown rice flour was mixed with a Chinese medical plant (Euryale ferox Salisb.) and processed to make ready‐to‐eat breakfast cereals using twin‐screw extrusion. Levels of 15 and 20% feed moisture in flour, and 200 and 250 rpm screw speed were set, and the physicochemical properties and content of α‐, β‐, γ‐, and δ‐tocopherols were determined. The data showed that 15% feed moisture gave a low bulk density and water absorption index but a high expansion ratio and water solubility index. High screw speed (250 rpm) produced a result similar to that of 15% feed moisture. A sample with 85% brown rice flour with 15% E. ferox Salisb. retained the highest content of α‐, β‐, γ‐, and δ‐tocopherols (125, 6, 78, and 9 μg/g), respectively. The optimum extrusion conditions determined were 15% E. ferox Salisb. mixed with brown rice at 15% feed moisture and at 250 rpm screw speed.     

Effect of Extrusion Conditions on Pasting Behavior and Microstructure of Refabricated Rice: A Response Surface Analysis

The effects of moisture, screw speed, and barrel temperature on pasting behavior of refabricated rice grains were investigated in a corotating twin‐screw extruder with response surface methodology. The rice flour obtained from broken rice (≤1/8 of actual kernel size) of PR‐116 variety was used in the study. The screw speed was set at five levels between 49 and 150 rpm, barrel temperature between 59 and 110°C, and feed moisture between 31 and 45%. All pasting properties of refabricated grains evaluated—peak viscosity, hold viscosity, breakdown viscosity, final viscosity, and setback viscosity—were significantly (P < 0.01) affected by the three process variables. Barrel temperature was the most significant variable, with quadratic effect on all viscosity parameters. Response surface regression models were established to correlate the viscosity profile of refabricated rice grains to the process variables. The optimum moisture content, screw speed, and barrel temperature estimated by a response surface of desirability function for the production of refabricated rice were 36%, 130 rpm, and 89.5°C, respectively. Scanning electron microscopy also revealed that intermediate moisture and temperature along with high screw speed during extrusion could create a more realistic appearance of refabricated rice with less rupture of starch granules.     

Effects of Steam,Moisture, and Screw Speed on Physical Properties of DDGS‐Based Extrudates

A fractional factorial design with a replicated central composite point was used to investigate the effects of extrusion processing on physical properties of distillers dried grains with solubles (DDGS) based aquafeeds using a twin‐screw extruder. Extrusion cooking trials were performed with a nutritionally balanced ingredient blend for Nile tilapia, with two levels of screw speed (350 and 450 rpm), two levels of extruder water (0.236 and 0.302 kg/min), and two levels of conditioner steam (0.1 and 0.15 kg/min). The central point was 400 rpm screw speed, 0.271 kg/min extruder water, and 0.12 kg/min conditioner steam. Effects of these processing conditions on extrudate characteristics were extensively analyzed and included moisture content, water activity, thermal properties, expansion ratio, unit density, bulk density, color, water stability, sinking velocity, water absorption and solubility indices, and pellet durability index. Increasing the extruder water and conditioner steam resulted in a 5.3% decrease and nearly 8.6% rise in mass flow rate, respectively. As screw speed increased from 350 to 400 rpm, water stability and water activity increased by 13 and 58%, respectively. Increasing extruder water from 0.236 to 0.302 kg/min led to a significant increase in water stability by 12.5% and decreases in water absorption index, water activity, and expansion ratio by 13, 21, and 5.5%, respectively. As conditioner steam increased from 0.1 to 0.15 kg/min, sinking velocity and water absorption index decreased by 25 and 15%, respectively. Increasing conditioner steam from 0.1 to 0.12 kg/min resulted in 20, 5.5, 10, and 3% decreases in moisture content of the extrudates, brightness (L*), water stability, and expansion ratio, respectively. It also increased bulk density by 5.8% and unit density by 4.2%. Overall, all trials produced viable extrudates with properties appropriate for Nile tilapia feeding.     

Effect of Temperature and Screw Speed on Stability of Fumonisin B1 in Extrusion-Cooked Corn Grits

Corn grits spiked with fumonisin B₁ (FB₁) at a level of 5 μg/g were extrusion cooked in a corotating twin-screw extruder at different temperatures (140, 160, 180, and 200°C) and screw speeds (40, 80, 120, and 160 rpm). Good recoveries of FB₁ were obtained from the nonextruded as well as the extruded grits by using high-performance liquid chromatography. Both the barrel temperature and the screw speed significantly (P ≤ 0.05) affected the extent of fumonisin reduction in extruded grits. As expected, the FB₁ recovered decreased with an increase in temperature and a decrease in screw speed. The amount of FB₁ lost from cooking grits at the different extrusion parameters used in this study ranged from 34 to 95%. About 46–76% of the spiked FB₁ was lost when the grits were cooked at temperatures and screw speeds that resulted in acceptable product expansion and color.     

Influence of Particle Size on the Twin-Screw Extrusion of Corn Meal

Effects of particle size (50–1,622 μm), screw speed (200–400 rpm), and feed moisture content (19–22%) on twin-screw extrusion of corn meal were investigated using a full-factorial design. Torque, specific mechanical energy, and product temperature generally showed no change within the commonly used particle-size range (100–1,000 μm), but each value dropped significantly as the particle size increased >1,000 μm. Die pressure was influenced by the three-way interaction of particle size, screw speed, and feed moisture content. The highest moisture level (22%), largest particle size (1,622 μm), and two lowest screw speeds (200 and 300 rpm) were the only conditions where the starch was <97.5% of transformation (gelatinization). Consequently, these two conditions also showed the least expansion and hardest product.     

Whole Grain Wheat Flour Production Using an Ultracentrifugal Mill

Interest has been growing in whole grain products. However, information regarding the influence of the ultracentrifugal mill on whole grain flour quality has been limited. An experiment was conducted to produce whole wheat flour with hard red spring (HRS) wheat using an ultracentrifugal mill. This study determined the effect of centrifugal mill parameters as well as grain moisture (10–16%) on producing whole wheat flour and its final products. Mill parameters studied were rotor speed (6,000–15,000 rpm) and feed rate (12.5–44.5 g/min). Results showed that fine particle size (<150 µm) was favored by low seed moisture content (10–12%) and high rotor speed (12,000–15,000 rpm). Flour moisture content was positively related to seed moisture content. Wheat grain with low seed moisture content (10–12%) milled with high rotor speeds (12,000–15,000 rpm) produced desirable whole grain wheat flour quality, with 70–90% of fine particle size portion and low damaged starch (less than 11%). This whole wheat flour produced uniform and machinable dough that had low stickiness and formed bread with high loaf volume.     

Effect of Extrusion Process Parameters on the Quality of Buckwheat Flour Mixes

A response surface analysis using a second-order central composite design was used to study the effect of extrusion process parameters on the extrudate quality of three blends containing buckwheat flour. The extrudates were prepared as three blends. Blend 1 was a 55:40:5 (w/w) mix of light buckwheat flour, wheat flour, and nonfat dry milk (NFDM). Blend 2 was a 40:55:5 mix of light buckwheat flour, corn meal, and NFDM. Blend 3 was a 30:60:10 mix of light buckwheat flour, corn meal, and NFDM. The blends were processed in a twin-screw extruder with factorial combinations of the parameters including: process temperatures of 95–150°C, dough moisture of 15–22%, and screw speeds of 260–390 rpm. The linear components alone significantly explained most of the variation of expansion index, bulk density, water absorption, and breaking strength. The greatest amount of variability was explained by process temperature for blend 1. Dough moisture accounted for the greatest amount of variation for blends 2 and 3. Maximum predicted expansion index values and high water absorption percentages were obtained at low dough moisture levels. Dough moisture and process temperatures were the most important factors predicting bulk density. Sensory evaluation of texture, color, flavor, and general acceptability scores of selected samples ranked blend 3 > blend 2 > blend 1. The in vitro protein digestibility values ranked blend 1 > blend 2 > blend 3. An increase of up to 9.5% units in the protein digestibility values was observed when compared to the nonextruded raw blends.     

Rapid Isolation of Sorghum and Other Cereal Starches Using Sonication

High‐intensity ultrasound (sonication) was investigated as a method to rapidly purify starch from sorghum and other cereal grains. To improve the process, buffers were optimized to solubilize sorghum proteins in combination with the sonication. Protein content and starch color were determined to evaluate the efficiency of the extraction process. Sonication times, SDS concentration, different types and concentrations of reducing agents (sodium metabisulfite, dithiothreitol, and β‐mercaptoethanol), and centrifugation speeds of the starch washing procedure were tested. Protein content of isolated sorghum starch was reduced to 0–0.14% (db) after 2 min of sonication (using any of the reducing agents tested). Sodium metabisulfite was chosen as the preferred reducing agent because of its lower toxicity and odor compared with other reducing agents tested. The optimum conditions for producing high‐purity sorghum starches (0.06% protein) were obtained using the following conditions: 2 min of sonication time with 12.5 mM sodium borate buffer, pH 10, containing 0.5% SDS (w/v) and 0.5% sodium metabisulfite (w/v) using 1,500 rpm centrifugation speed during starch washing. Starches separated by this method showed significantly less protein content and b values (yellowness) compared with starches separated by enzymatic methods or methods using NaCl solutions and protein extraction buffers with multiple washing steps, both of which take several hours to complete. Differential scanning calorimetry thermogram values for starches isolated by three different methods showed similar patterns, except that starches obtained with the enzymatic method had slightly higher values of T_o, T_p, and ΔH. Other cereal starches from whole wheat meal, wheat flour, corn, rice, and barley were also obtained rapidly using sonication.     

Effects of Extrusion Variables and Chemicals on the Properties of Starch-Based Binders and Processing Conditions

The effects of extrusion variables (moisture, screw speed, and temperature) and chemicals (urea and sodium bicarbonate) on the properties of starch-based binders (water absorption, bulk density, binder yield, expansion ratio, solubility, pH) and processing conditions (die temperature and pressure, feed rate, and specific mechanical energy) were studied using a central composite design. All quadratic regression models, except the models for bulk density and pH, were significant at the P ≤ 0.06 level. These models can predict the binder properties and processing conditions when extrusion variables and the chemical concentrations are known. Optimum combinations of the chemical concentrations (g/100 g of starch) and extrusion variables to achieve high water absorption in the binders were 15–20 g of urea /100 g of starch, 0–4 g of sodium bicarbonate/100 g of starch, 35–40 g of moisture/100 g of starch, 100–120 rpm screw speed, and 185–215°C barrel temperature. The molecular degradation of the starch occurred during extrusion, especially when the moisture content of starch was <30 g/100 g of starch.     

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

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

Effects of Flour Extraction Rate,Added Water,and Salt on Color and Texture of Chinese White Noodles

Both cultivar and noodle composition and preparation have important effects on noodle quality. In this study, the effects of flour extraction rate (50, 60, and 70%), added water (33, 35, and 37%), and salt concentration (0, 1, and 2%, w/w) on color and texture of Chinese white noodle (CWN) were investigated using flour samples from five leading Chinese wheat cultivars. The five samples showed large variations in protein content, ash content, flour color, farinograph, and extensigraph parameters, and starch pasting properties. Analyses of variance indicated that cultivar, flour extraction rate, level of water addition, salt concentration, and the interactions had significant effects on color of raw noodle sheets and color and textural properties of CWN. Cultivar and water addition were more important sources of variation than flour extraction rate and salt concentration. The brightness (L*) and redness (a*) values of raw noodle sheets were significantly reduced and increased, respectively, as flour extraction rate increased from 50 to 70%, and noodle scores were slightly higher at flour extraction rates of 50%. Water addition showed different effects on raw noodle sheet color at 2 and 24 hr, and a significant improvement was observed for noodle appearance, firmness, viscoelasticity, smoothness, and total score as water addition increased from 33 to 37%. L* of raw noodle sheets, and firmness and viscoelasticity of cooked noodles, were significantly improved, but noodle flavor significantly deteriorated as salt concentration increased from 0 to 2%; 1% salt produced the highest noodle score. Thus, the recommended composition for laboratory preparation of CWN is 60% flour extraction, 35% water addition, and 1% salt concentration.     

Oil Absorption Characteristics of a Multigrain Extrudate During Frying: Effect of Extrusion Temperature and Screw Speed

The oil absorption characteristics of a multigrain extruded and fried snack product were studied as a function of extruder screw speed and cooking temperature using a central composite response surface methodology (RSM). The extruded product was produced using a corotating twin screw extruder, dehydrated to a uniform moisture content, and subsequently deep‐fat‐fried at 192 ± 1°C for 10–40 sec to complete expansion. Significant RSM models were developed for oil absorption and extrudate water absorption index (WAI). According to the lowest oil model, absorption (19.9%) was obtained with an extruder screw speed of 218.6 rpm and a cooking temperature of 117.8°C. WAI reached a maximum at a screw speed of 221.9 rpm and a cooking temperature of 109°C. Oil absorption characteristics and extrudate WAI were significantly correlated (r= ‐0.84, P = 0.0002). The data suggest that extrusion conditions can be optimized to influence the physicochemical structures in the extrudate matrix so that oil absorption can be minimized.     

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.     

Formation of Resistant Starch by a Twin-Screw Extruder

The objective of this study was to evaluate the potential to increase the level of resistant starch (RS) in extruded products by optimizing extruder conditions. Three experiments were conducted as randomized complete block designs with two replicates. In the first experiment, corn starch, wheat starch, and potato starch were added at a level of 30% (w/w) to degerminated yellow corn meal to investigate the influence of starch type. In the second experiment, citric acid (CA) monohydrate was added to corn meal at levels of 0, 2.5, 5, and 7.5% (w/w). The third experiment was a full-factorial arrangement to evaluate the effect of high-amylose corn starch (HACS) level (0, 15, 30%, w/w) and CA level (0, 5, 7.5%, w/w) at two screw speeds (200 and 300 rpm). In the first experiment, the means for RS plus dietary fiber for the different starch formulations ranged from 1.27 to 2.28%. In experiment 2, adding CA increased RS plus dietary fiber content to a maximum of 5.23% at 7.5% CA. In the third experiment, the means for RS plus dietary fiber ranged from a low of 1.75% for 100% corn meal at 300 rpm to 14.38% for 7.5% CA and 30% HACS at 200 rpm. The results indicated a highly significant positive relationship between CA and RS formation and the same for amylose content. The RS formation had a negative relationship with screw speed, but the influence of screw speed was small when compared with that of CA and HACS.     

Effect of DDGS,Moisture Content,and Screw Speed on Physical Properties of Extrudates in Single‐Screw Extrusion

Three isocaloric (3.5 kcal/g) ingredient blends containing 20, 30, and 40% (wb) distillers dried grains with solubles (DDGS) along with soy flour, corn flour, fish meal, and mineral and vitamin mix, with net protein adjusted to 28% (wb) for all blends, were extruded in a single‐screw laboratory‐scale extruder at screw speeds of 100, 130, and 160 rpm, and 15, 20, and 25% (wb) moisture content. Increasing DDGS content from 20 to 40% resulted in a 37.1, 3.1, and 8.4% decrease in extrudate durability, specific gravity, and porosity, respectively, but a 7.5% increase in bulk density. Increasing screw speed from 100 to 160 rpm resulted in a 20.3 and 8.8% increase in durability and porosity, respectively, but a 12.9% decrease in bulk density. On the other hand, increasing the moisture content from 15 to 25% (wb) resulted in a 28.2% increase in durability, but an 8.3 and 8.5% decrease in specific gravity and porosity, respectively. Furthermore, increasing the screw speed and moisture content of the blends, respectively, resulted in an increase of 29.9 and 16.6% in extruder throughput. The extrudates containing 40% DDGS had 8.7% lower brightness, as well as 20.9 and 16.9% higher redness and yellowness, compared with the extrudates containing only 20% DDGS. Increasing the DDGS content from 20 to 40% resulted in a 52.9 and 51.4% increase in fiber and fat content, respectively, and a 7.2% decrease in nitrogen free extract. As demonstrated in this study, ingredient moisture content and screw speed are critical considerations when producing extrudates with ingredient blends containing DDGS, as they are with any other ingredients.     

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

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

Composition,Functional Properties,Starch Digestibility,and Cookie‐Baking Performance of Dry Bean Powders from 25 Michigan‐Grown Varieties

The chemical composition, functional properties, starch digestibility, and cookie‐baking performance of bean powders from 25 edible dry bean varieties grown in Michigan were evaluated. The beans were ground into coarse (particle size ≤1.0 mm) or fine (≤0.5 mm) powders. Starch and protein contents of the bean powders varied between 34.4 and 44.5% and between 19.1 and 26.6% (dry basis [db]), respectively. Thermal properties, pasting properties, and water‐holding and oil‐binding capacities of the bean powders differed and were affected by particle size. After blending the bean powders with corn starch (bean/starch = 7:3, db), the blends were used for cookie baking following a standard method ( 1 Approved Method 10‐54.01). Generally, the cookies baked from the fine bean powders had smaller diameters, greater thicknesses, and greater hardness values than those from the coarse counterparts. Differences in the cookie‐baking performances of the bean powders were observed among the 25 varieties. Larger proportions of resistant starch (RS) were retained in the bean‐based cookies (54.7–126.7%) than in the wheat‐flour‐based cookies (10.4–19.7%) after baking. With higher contents of RS and protein, the bean‐based cookies had more desirable nutritional profiles than those baked from wheat flour alone.     

Waxy Soft White Wheat: Extrusion Characteristics and Thermal and Rheological Properties

Waxy wheat flour was analyzed for its thermal and rheological properties and was extruded to evaluate its potential for extruded products. Normal soft white wheat flour was analyzed with the same methods and same extrusion conditions to directly compare differences between the two types of flour. Through DSC analysis, waxy wheat flour was found to have a higher gelatinization peak temperature of 66.4°C than normal wheat at 64.0°C, although the transition required 2.00 J/g less energy. Rapid visco‐analysis indicated that the waxy wheat flour pasted much more quickly and at lower temperatures than the normal wheat flour. Preliminary extrusion experiments were conducted to determine the optimal screw profile for waxy wheat with respect to maximum radial expansion. The optimum screw profile was used for extrusion trials with varying flour moisture (15–25% wb) and extruder screw speed (200–400 rpm) while monitoring process conditions including back pressure and specific mechanical energy. Physical properties of the extrudates were then studied. The radial expansion ratios of the waxy wheat extrudates exceeded those of the normal wheat extrudates by nearly twice as much, and it was observed that the waxy wheat flour took less energy in the form of fewer shear screw elements to expand. The waxy wheat extrudates also exhibited significantly higher water solubility and less water absorption than the normal wheat extrudates owing to solubilizing of the extrudates. The results of our study indicate that waxy wheat flour may be a viable ingredient for creating direct expanded products with less energy.     

Isolation and Characterization of Cotyledon Fibers from Peas,Lentils, and Chickpeas

Methods were developed to efficiently isolate legume cotyledon fibers with relatively high yields and purities. Seeds of pea (Pisum sativum), chickpea (Cicer arientinum), and lentil (Lens culinaris) were roller milled into flour and fractionated into prime starch, tailings starch, and water solubles. Insoluble dietary fiber was isolated from tailings starch by wet screening on sieves with openings ranging from 53 to 90 μm. Yield of insoluble fiber using a sieve with 53‐μm openings ranged from 49.7 to 59.2% of insoluble fiber in flour with purities ranging from 85.5 to 87.3%. Soluble dietary fiber was isolated from the water‐soluble fraction following acid precipitation of soluble protein at pH 4. Soluble fiber yield ranged from 83.3 to 89.6% of flour soluble fiber with purities ranging from 64.5 to 70.6%. Glucose was the most common sugar component of hulls and soluble cotyledon fibers, while arabinose was the main sugar in insoluble fibers. Insoluble fiber exhibited significantly higher swelling capacities and water and oil binding capacities in comparison to hulls and soluble cotyledon fibers. Apparent viscosities of soluble cotyledon fibers ranged from 3.13 to 3.43 Pa•sec and exhibited Newtonian characteristics.     

Small‐Scale Extrusion of Corn Masa By‐Products

Corn masa by‐product streams are high in fiber and are amenable for utilization in livestock feed rations. This approach is a potentially viable alternative to landfilling, the traditional disposal method for these processing residues. Suspended solids were separated from a masa processing waste stream, blended with soybean meal at four levels (0, 10, 20, and 30% wb), and extruded in a laboratory‐scale extruder at speeds of 50 rpm (5.24 rad/sec) and 100 rpm (10.47 rad/sec) with temperature profiles of 80‐90‐100°C and 100‐110‐120°C. Processing conditions, including dough and die temperatures, drive torque, specific mechanical energy consumption, product and feed material throughput rates, dough apparent viscosity, and dough density, were monitored during extrusion. The resulting products were subjected to physical and nutritional characterization to determine the effects of processing conditions for these blends. Extrudate analysis included moisture content, water activity, crude protein, in vitro protein digestibility, crude fat, ash, product diameter, expansion ratios, unit and true density, color, water absorption and solubility, and durability. All blends were suitable for extrusion at the processing conditions used. Blend ratio had little effect on either processing parameters or extrudate properties; extrusion temperature and screw speed, on the other hand, significantly affected both processing and product properties.