Physical and biochemical properties of maize hardness and extrudates of selected hybrids

Protein and starch determinants of maize kernel hardness and extruded products were characterized to better define the role of endosperm texture during extrusion. Maize physical properties were correlated with total proteins and zein subclasses (p < 0.01). The extrusion process significantly altered protein solubility and increased protein fragmentation as measured by RP-HPLC and size exclusion chromatography. Harder grits and extrudates demonstrated higher amylose content, lower degree of starch damage, and fragmentation at different screw speeds than softer grits and extrudates. Differences in extrudate expansion ratio, water absorption index, water solubility index, oil absorption capacity, and breaking stress between harder and softer hybrids were related to protein aggregation and fragmentation as well as starch damage and fragmentation.     

Physical Properties of Extruded Wheat Starch-Additive Mixtures

The effects of the addition of fatty acids, monoglycerides (MG), and wheat germ oil (WGO) on the level of crystallinity and the crystalline structure of extrusion-cooked wheat starch have been studied using twin-screw extruders. Measurements of water solubility and water absorption indices were made on the extrudates, together with specific mechanical energy (SME) consumption and die pressure for the extruder. MG and the fatty acids added to a level of 4% caused an increase in V_hydrate type crystallinity. WGO addition to a level of 8% caused no change in crystallinity, although the E_hydrate type was favored at lower moisture contents. All additives caused a decrease in SME and an increase or maximum in die pressure. WGO behaved differently than MG and fatty acids in that its addition caused the water solubility index and expansion to increase, as previously observed for other oils added to flours.     

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 Corn Moisture on the Properties of Pet Food Extrudates

Corn moisture (9.5–13.5%) was significantly correlated to extrudate properties, even though water was added at the extruder to compensate for the differences in moisture. Water addition was more effective at the preconditioner than at the extruder, and longer retention preconditioner improved expansion. Water added to the pet food formula apparently was absorbed by the other formula ingredients and not the corn. Controlling the specific mechanical energy did not compensate for differences in corn moisture.     

Functional Properties of Polylactic Acid Starch‐Based Loose‐Fill Packaging Foams

In this study, attempts were made to improve the characteristics of starch‐based plastic foams by blending starch with polylactic acid (PLA), a biodegradable polymer made from renewable sources. Formulations of the foams (types of starch, ratio of starch to polymer, and moisture content) were optimized. Physical and mechanical properties of the foams, including expansion, unit density, bulk density, water solubility index (WSI), spring index, and compressibility on both single piece and bulk samples were determined. The addition of the PLA polymer to regular (25% amylose) and waxy corn starches significantly improved the physical and mechanical properties of the extruded foams. Foams made from waxy starch had better radial expansions, higher WSI, higher compressibilities, and lower spring indices than those of regular starch foams. Both regular and waxy starches produced foams with similar unit and bulk densities, bulk compressibilities, and bulk spring indices. Increasing PLA polymer contents increased the radial expansions and spring indices and significantly reduced the unit and bulk densities and bulk compressibilities. Changing the PLA content had no significant effect on WSI, compressibilities, and bulk spring indices. Increasing the moisture content adversely affected foam characteristics. The formulation containing waxy starch, 40% PLA, and 19% moisture produced a loose fill foam with the best physical characteristics and mechanical properties.     

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.     

Effects of Calcium Hydroxide and Processing Conditions on Corn Meal Extrudates

The effects of added calcium hydroxide (0.0, 0.15, 0.25, and 0.35%) and processing conditions, feed moisture content (mc) (16, 18, and 20%) and barrel temperature (130 and 150°C) on characteristics of corn meal extrudates were studied. Extruder screw speed was maintained at 130 rpm. Corn meal was extruded with a single-screw extruder (Brabender model GNF 1014/2) with a screw compression ratio of 3:1. The highest values (P < 0.05) for radial expansion and the lowest values for density and breaking force of extrudates were found for the treatment with 0.00% calcium hydroxide extruded at 16% feed mc and 130°C barrel temperature. This treatment was statistically different from the other treatments. Best values for radial expansion of samples extruded with added calcium hydroxide were for the samples with 0.15% calcium hydroxide at 18% feed mc and 130°C barrel temperature, followed by the sample with 0.35% calcium hydroxide at 16% feed mc and 130°C barrel temperature. Water absorption index and water solubility index were affected by calcium hydroxide and extrusion conditions evaluated. Extrudates had large numbers of flattened and sheared granules. Increases in calcium hydroxide increased extrudate yellowness. The combined action of calcium hydroxide and extrusion conditions completely modified the organized structure of the starch and suggest the formation of a starch-calcium complex (crystalline region). The texture of the extruded products was crispy after puffing.     

Effect of Separation and Grinding of Corn Dry-Milled Streams on Physical Properties of Single-Screw Low-Speed Extruded Products

Three streams of corn dry-milled products (corn grits, corn cones, and corn flour) were sieved and separated according to average diameter, and some segregated fractions were ground to produce nine streams. Corn grits were separated to produce grits with diameters of 1.19 and 0.841 mm, and selected fractions were ground into grits with average diameters of 0.297 and 0.210 mm. Corn cones were separated into average diameters of 0.595, 0.420, and 0.297 mm. Corn flour was separated into fractions with average diameters of 0.297 and 0.210 mm. The original and the additional streams were extruded at constant speed (50 rpm) and at three different processing extruder barrel temperature profiles: low (LTP, 100-110-120°C), medium (MTP, 110-120-130°C), and high (HTP, 120-130-140°C). The least significant difference (P < 0.01) test showed that additional grinding of corn grits affects the expansion ratio of extrudates processed at LTP and HTP. Additional separation of corn flour affects (P < 0.01) the bulk density and water solubility index of extrudates at HTP. At HTP, corn cones with diameters of 0.595 mm had significantly (P < 0.01) higher torque, specific mechanical energy, and die pressure than did the original corn cone extrudates without separation.     

Modifications to physicochemical and nutritional properties of hard-To-cook beans (Phaseolus vulgaris L.) by extrusion cooking.

The objective of this work was to evaluate extrusion cooking as a means to improve the nutritional properties of Phaseolus vulgaris L. that had been stored either at 42 degrees C and 80% relative humidity for 6 weeks or for periods >1 year in cereal stores in tropical conditions. Storage under these conditions resulted in an increase in cooking time increased (7.7- and 12-fold, respectively) as a result of development of the hard-to-cook (HTC) defect. Single-screw extrusion of the milled beans was carried out at four barrel temperatures and two moisture contents. The extrudate bulk density and water solubility index decreased with increasing temperature, whereas the water absorption index increased due to the higher proportion of gelatinized starch in the extruded samples. Both fresh and HTC beans contained nutritionally significant amounts of lectins, trypsin, and alpha-amylase inhibitors, which were mostly inactivated by extrusion. Extrusion also caused a considerable redistribution of insoluble dietary fiber to soluble, although the total dietary fiber content was not affected. Changes in solubility involved pectic polysaccharides, arabinose and uronic acids being the main sugars involved. Stored beans subjected to extrusion cooking showed physical and chemical characteristics similar to those of extrudates from fresh beans.     

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.     

Physical Properties of Poly(Lactic Acid) and Starch Composites with Various Blending Ratios

Two‐phase polymer blends of poly(lactic acid) (PLA) and corn or wheat starches at various ratios were prepared by using a laboratory‐scale twin‐screw extruder and compression molding. The blends were characterized for thermal transitions, mechanical properties, and water absorption. Starch and PLA were immiscible polymers, and the thermal behavior of PLA was not affected by starch. Crystallinity of the blends decreased in some degree as starch content increased 20–40%. Tensile strength and elongation of the blends decreased as starch content increased, but modulus increased as starch content increased up to 70%. As starch content increased to >60%, the PLA phase became discontinuous, and water absorption of the blends increased sharply. Blends made from wheat starch gave slightly better mechanical properties than those made from corn starch, and no differences in other properties were observed.     

Effects of Corn Sample,Mill Type,and Particle Size on Corn Curl and Pet Food Extrudates

The effects of corn sample, grinder type, and particle size of ground corn on the extrusion of corn curls and pet food were studied. Extrusion runs were conducted using a twin-screw extruder. Properties of corn curl and pet food extrudates were affected significantly by corn samples obtained from different parts of the country (Nebraska, Illinois, and Texas), even though grinding and extrusion parameters were held constant. The type of grinder used to grind the corn had an effect on extrusion properties. The volumetric expansion index (VEI) of extrudate from pin-milled samples was lower than that of extrudate from the same corn ground in a hammer mill or roller mill. Small particle size, obtained by grinding corn in a hammer mill with different screen sizes, produced extrudate with a significantly higher VEI than extrudate from coarse- or medium-sized particles.     

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.     

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.     

Properties and Microstructure of Zein Sheets Plasticized with Palmitic and Stearic Acids

Interest in biodegradable materials for packaging and agricultural uses has grown in recent years. Plant proteins have been proposed as inexpensive, renewable, and abundant feedstock. Corn zein was investigated based on value-added considerations and on the unique thermoplastic and hydrophobic properties of zein. Films prepared from zein are known to be tough and resistant, but also hard and brittle, thus requiring the addition of plasticizers to improve flexibility. The objectives of this research were to study the tensile properties, water absorption, and microstructure of zein sheets plasticized with palmitic and stearic acids. Both palmitic and stearic acids showed similar effects as plasticizers of zein. Tensile strength of zein sheets increased with the addition of low levels of plasticizers. However, beyond a critical point, tensile strength decreased with further addition of fatty acids. Water absorption decreased continuously with increasing fatty acid content. Kinetic parameters indicated fatty acids decreased water absorption by decreasing the saturation level of zein sheets. Coating zein with flax oil decreased the rate of water absorption by sealing off surface pores. Scanning electron micrographs of zein sheets showed the development of layered structures as fatty acid content increased. Zein-fatty acid layers were believed to be responsible for the increased tensile strength of plasticized zein sheets and to have contributed to increased resistance to water absorption.     

Effects of Selected Harvest Moistures and Frozen Storage Times on Selected Yellow Dent Corn: Wet‐Milling Yields and Starch Pasting Properties

The effects of harvest moistures and frozen storage times on corn wet‐milling yields and the pasting properties of the resulting starch were studied. Pioneer hybrid P‐0916‐XR harvested at three moisture contents (49, 35, and 21% wb) were stored frozen for three days or for five months, followed by wet‐milling. The pasting properties of the resulting starch were evaluated with a Rapid Visco Analyzer. The yields of starch and germ increased by 1.2 and 1.9 percentage points, respectively, when harvest moisture decreased from 49 to 21% wb, whereas the yields of steep water solids, total fiber, and gluten decreased by 2.1, 0.7, and 0.6 percentage points, respectively. The frozen corn had lower coarse fiber yields but higher cellular fiber yields. The starch pasting properties showed that peak and breakdown viscosities decreased by 8% (3,824 ± 36 versus 3,520 ± 38 cP) and 13% (2,336 ± 47 versus 2,029 ± 60 cP), respectively, when harvest moisture decreased from 49 to 21% wb, whereas peak time increased by 5% (6.32 ± 0.06 versus 6.62 ± 0.07 min). The setback and final viscosities of starch from long‐term frozen storage (five months) were 14% (1,574 ± 65 versus 1,828 ± 79 cP) and 8% (3,063 ± 27 versus 3,317 ± 101 cP) lower, respectively, than that from control (unfrozen) corn.     

Twin-Screw Extrusion Processing of Feed Blends Containing Distillers Dried Grains with Solubles (DDGS)

Extrusion trials were conducted with varying levels of distillers dried grains with solubles (DDGS) along with soy flour, corn flour, fish meal, vitamin mix, mineral mix, and net protein content adjusted to 28% using a Wenger TX-52 twin-screw extruder. The properties of extrudates were studied in experiments conducted using a full-factorial design with three levels of DDGS content, two levels of moisture content, and two levels of screw speed. Increasing the DDGS content from 20 to 60% resulted in a 36.7% decrease in the radial expansion, leading to a 159 and 61.4% increase in the unit density and bulk density of the extrudates, respectively. Increasing the DDGS content resulted in a significant increase in the water absorption index (WAI) but a significant decrease in the water solubility index (WSI) of the extrudates. Changing the screw speed and moisture content had no significant effect on the radial expansion ratio but resulted in a significant difference in the bulk density of the extrudates, which may be due to the occurrence of longitudinal expansion. Even though changing the moisture content and screw speed had no significant effect on the WSI of the extrudates, significant differences in the WAI of the extrudates were observed. The ingredient components in the blend and moisture content had an influence on the color changes of the extrudates, as did the biochemical changes occurring inside the barrel during processing. Overall, it was determined that DDGS could be included at a rate of up to 60% using twin-screw extrusion, and that viable pelleted floating feeds can be produced.     

Physical Properties of Extruded Strands of Hydroxypropylated Normal and High-Amylose Corn Starch

Normal (25% amylose) and high-amylose (70% amylose) corn starches (CS and HA) were hydroxypropylated to 0.1 degree of molar substitution (MS) with propylene oxide in an alkaline-ethanol medium (70% ethanol). CS and hydroxypropylated corn starch (HPCS) were mixed on dry basis with water and glycerol at a weight ratio of 7:2:1, and HA and hydroxypropylated high amylose corn starch (HPHA) were mixed at 7:3:1. Stearic acid, glycerol monostearate, or lecithin (3%, based on starch) was added to each mixture to examine the effects on the physical properties of the extrudate. The starch mixtures were extruded at high shear (100 rpm) to nonexpanded strands using a corotating twin-screw extruder in a temperature range of 75–90°C. HA, alone and with all additives, showed lower die swelling in extrusion than did CS, whereas HPCS and HPHA showed higher die swelling than the corresponding unmodified starches. Water absorption of all HA extrudates was lower than those of all CS extrudates (22–35% and 68–97%, respectively, at 25°C). Hydroxypropylation increased the absorption for both starches. All extruded starches, regardless of additives, showed low solubility in water (0.1–1.0% for 2 hr at 25°C). Differential scanning calorimetry indicated that during extrusion, the lipid additives formed a helical complex with amylose in CS and HA, but weakly with HPCS and HPHA. The extruded strands of HA, alone and with additives, exhibited higher tensile and bending strengths (37.1–58.4 and 2.16–5.07 MPa, respectively), compared to the CS strands (12.5–59.3 and 1.06–4.10 MPa, respectively) at the same moisture content (7.5–8.5%). Both tensile strength and percent of elongation of the starch strands were reduced by the presence of a lipid additive. Hydroxypropylation increased elongation and flexibility of the extrudates. HPHA exhibited the greatest mechanical strength and flexibility among the tested starches.     

Effect of Additional Separation and Grinding on the Chemical and Physical Properties of Selected Corn Dry-Milled Streams

Three streams of corn dry-milled products (corn grits, corn cones, and corn flour) from three different commercial corn dry-millers were further separated by particle size according to the major portion of each stream. They were separated into corn grits (1.190 and 0.841 mm), corn cones (0.595, 0.420, and 0.297 mm), and corn flour (0.297 and 0.210 mm). Besides separation, corn grits were also ground and then separated into ground corn grits (0.297 and 0.210 mm). The original streams, streams with additional separation, and streams with additional grinding were analyzed for protein content, ash content, crude fat content, and color properties. Duncan's significant difference tests (P < 0.01) showed that additional separation and grinding of the commercial corn grits, corn cones, and corn flour affected protein, crude fat content, and color parameter (L, a, and b) distribution of the products. The tristimulus parameters (L, a, and b) were good indicators of the protein content of the corn dry-milled streams studied.     

Factors Affecting Expansion of Corn Meals with Poor and Good Expansion Properties

Two corn meals, one with good and one with poor expansion properties, were used to study the critical factors responsible for poor expansion during corn curl extrusion. Screening tests revealed that the corn meal with poor expansion had a slightly larger particle size. This sample also had a larger proportion of opaque particles compared to the corn meal with good expansion. Extrusion of coarse corn grits showed that larger particle size alone could cause poor expansion. Water diffusion tests showed that the sample containing more opaque particles was more competitive for water. As a result, in corn that contained both opaque and vitreous particles less water was available to the vitreous particles. The underplastisized (dry) vitreous particles remained glassy (unmelted) during extrusion, resulting in reduced expansion of the extrudates. The results suggest that addition of water to the conditioning cylinder of the extruder would overcome poor expansion.