Effect of extrusion cooking on chemical structure,morphology, crystallinity and thermal properties of sorghum flour extrudates

The effect of feed moisture content (10, 14 and 18%) and die temperature (110 and 160 °C) on functional properties, specific mechanical energy (SME), morphology, thermal properties, X-ray diffraction pattern (XRD), Fourier transform infrared spectroscopy (FTIR) and amylose-lipid complex formation of extruded sorghum flour was investigated. Results showed that the extrusion cooking significantly changed the functional properties of extruded sorghum flour. Increasing feed moisture increased the peak gelatinization temperature (T_p), the degree of gelatinization (%) and starch crystallinity (%) while it decreased the gelatinization temperature ranges (T_c - T₀), starch gelatinization enthalpy (ΔH_G) and amylose-lipid complex (%) formation. With increasing die temperature, the degree of gelatinization and amylose-lipid complex formation increased and the starch T_p, T_c-T₀, ΔH_G and crystallinity decreased. The FTIR spectra also showed that the extrusion cooking did not create new functional groups or eliminate them in sorghum protein, whereas the sorghum extrudate protein had random coil conformation.     

Physical Properties of Extruded Products from Three Mexican Common Beans (Phaseolus vulgaris L.) Cultivars

The physical properties of extruded products from three Mexican common bean cultivars were investigated. Common bean cultivars Flor de Mayo, Pinto Villa and Bayo Victoria from the same harvesting season (2006) were used in this work. Beans were milled and the flour was hydrated to 24, 26 and 28 g of water/100 g of dry weight. Two temperatures, 130 degrees C and 165 degrees C at the end of the extruder barrel without die, were experimented. Common bean flour extrudates were evaluated for water absorption index (WAI), water absorption capacity (WAC), oil absorption capacity (OAC), and emulsifying capacity (EC). Flor de Mayo extrudates showed the highest WAC and WAI values. Thus starch from Flor de Mayo beans showed minor restricted water availability. In all cases, the OAC of extruded products was lower than the crude bean flour. The EC for Bayo Victoria flour increased as a consequence of the extrusion process. The EC for Flor de Mayo was higher at lower temperature and lower moisture content than Pinto Villa and Bayo Victoria beans. EC behavior of Pinto Villa was similar to Bayo cultivar. These results indicate that it is possible to produce new extruded products with good physical properties from these common bean cultivars.     

Phytic acid content and “in vitro” iron, calcium and zinc bioavailability in bakery products: The effect of processing

Whole-grain bakery products and cereals are valuable sources of dietary fiber, vitamins, and trace elements. However, the presence of phytate, could decreases mineral bioavailability due to its chelating properties. In this study, the effect of fermentation and baking on the phytate content of different bakery products was measured by HPLC; the mineral availability in bakery products during processing was investigated by measuring solubility and dialysis, as well as the mineral uptake and transport by Caco-2 cells after in vitro digestion. Raw materials showed the highest amount of phytate, causing an important effect on the stage of processing. The solubility and dialyzability of iron increased with fermentation, meanwhile calcium and zinc showed a high variability depending on the product analyzed. After baking, the dialyzability of minerals increased with respect to the fermented dough in most cases. The highest uptake and transport efficiency of iron and calcium in cells corresponded to dough after fermentation of wheat flour with respect to the baked samples. For zinc, no differences were observed between fermented dough and after baking on uptake and transport efficiencies. This study showed that in vitro mineral availability of bakery products is influenced by the stage of processing and ingredients used.     

Changes in the Solubility of Corn Proteins through Interaction with the Arabinoxylans in Extruded Nixtamalized Corn Flour Treated with Xylanase

The extrusion process allows the production of nixtamalized corn flour rich in arabinoxylans, which help to prevent cardiovascular and intestinal diseases. During extrusion, physiochemical properties of nixtamalized corn flour are negatively modified. The use of enzymes such as xylanase in order to obtain nixtamalized corn flour using extrusion has been studied as an alternative to reduce these changes in corn flour tortilla. The aim of this research was to evaluate changes in protein solubility of extruded nixtamalized corn flour with and without different concentrations of xylanase enzyme (0.05, 0.075, and 0.1 %, w/w). Soluble proteins of each corn flour were extracted and analyzed by SE-HPLC, while insoluble proteins were determined by the combustion method. In addition, each corn flour was analyzed by scanning electron microscopy (SEM). Results showed that the extruded nixtamalized corn flour, with and without xylanase, increased the protein solubility, and this effect was lower in extruded nixtamalized corn flour with xylanase. Insoluble protein diminished in corn flours either with or without xylanase enzyme. The addition of xylanase reduces the effect that the extrusion process has on the solubility proteins of extruded nixtamalized corn flour.     

Effect of extrusion cooking of sorghum flour on rheology,morphology and heating rate of sorghum–wheat composite dough

Addition of a gluten-free flour such as sorghum has negative impact on the quality of wheat dough for bread making. One of the methods which can be used to promote the quality of sorghum-wheat composite dough is to extrude the sorghum flour before incorporation. In this regard, to produce a dough with appropriate bakery properties sorghum flour was extruded at 110 °C and 160 °C die temperature with 10%, 14% and 18% feed moisture. The effect of extruded sorghum flour incorporation (10%) on rheological (farinography and stress relaxation behavior), morphological and temperature profile of sorghum-wheat composite dough were evaluated. Extrusion cooking altered the sorghum-wheat composite dough properties through partial gelatinization of starch granules. Addition of extruded sorghum flour increased the water absorption and dough development time but it decreased the dough stability. Native sorghum-wheat composite dough showed viscoelastic liquid-like behavior whereas addition of sorghum flour extrudate changed dough to a more viscoelastic solid-like structure. Maxwell model was more appropriate than Peleg model to describe the viscoelasticity of the sorghum-wheat composite dough. Extrusion cooking decreased composite dough elasticity and viscosity. Sorghum extrudate increased the heating rate of composite dough crumb during baking. Addition of extruded sorghum flour formed a non-uniform and less compact dough structure. As a result, dough containing extruded sorghum flour had a good potential for producing a high-yielding bread in a short time of baking.     

Process,structure and texture of extruded whole wheat

Whole wheat is well known by consumers as a health-providing ingredient. Nevertheless, in extruded products it leads to textures that are less favorable to consumer preference compared to its refined flour. An understanding of the effect of extrusion on whole wheat properties is therefore necessary to improve its texture. Whole wheat flour was extruded under varying conditions of water content (18 or 22%), screw speed (400 or 800 rpm) and barrel temperature (140 or 180 °C) and its physicochemical properties were measured. Changing the extrusion conditions significantly modified the volumetric expansion index (between 9.1 and 20.6) and longitudinal expansion (between 0.93 and 2.98) of the samples. Interestingly, changing the extrusion conditions did not significantly modify the sectional expansion. Increasing barrel temperature, water content or screw speed decreased the shear viscosity of the melt. This can be explained by plasticizing effects and modification of starch properties. The change in shear viscosity at the die can mostly explain the effect of process conditions on volumetric expansion of the extruded whole wheat. The stress at rupture of the extruded samples was varied between 0.49 and 1.86 MPa depending on process conditions. It was the lowest at high water content and low screw speed.     

Effect of extrusion process variables on physical and chemical properties of extruded oat products

The purpose of this research was tostudy the effects of initial moisture levels andextrusion temperatures on bulk density, waterabsorption and water solubility indexes, viscosity,and color of extruded oat products. The dehulledgrains were ground in a Brabender Quadrumat Seniormill and the coarse fraction, with higher amounts ofcrude protein, lipids, and dietary fiber content, wereconditioned to moisture levels of 15.5–25.5% andextruded in a Brabender single-screw laboratoryextruder. The water absorption index of extrudateswere relatively low (4.16–6.35 g gel/g sample) butincreased as the initial moisture of the raw materialas well as the extrusion temperature was elevated.The water solubility index was inversely proportionalto the extrusion temperature. Initial viscosity of thepaste increased with the increase of raw materialmoisture and extrusion temperature, while the maximumviscosity (at a constant temperature) diminished withthe increase of temperature. Products with lowervalues of L* (luminosity) and greater values ofa* (red) and b* (yellow) were obtained athigh moisture rates and at a 120 ^°C extrusiontemperature.     

Rheological properties of pasta dough during pasta extrusion: Effect of moisture and dough formulation

A study was conducted to investigate the effect of dough formulation and hydration level on the rheological properties of pasta dough during pasta extrusion. Semolina 100%, whole wheat 100%, and the following mixtures semolina-whole wheat (49:51), semolina-flaxseed flour (90:10), whole wheat-flaxseed flour (90:10), and semolina-whole wheat-flaxseed flour (39:51:10) were the formulations used for the experiments. Dough was hydrated at 30, 32, and 34% moisture content. Pasta was extruded with a capillary and a semi-commercial pasta extruder to determine the apparent viscosity of the dough during extrusion conditions and its relationship to the behavior of the dough during pasta processing. Results showed that non-traditional pasta dough behaved like a shear thinning fluid that can be described by the Power Law model. Increased hydration levels and/or presence of flaxseed flour on the dough formulation decreased the apparent viscosity of the dough, which correlated with extrusion pressure, mechanical energy, and specific mechanical energy that were required to extrude the dough in the pasta extruder. The strong correlations found between the apparent viscosity of the dough and the pasta extrusion parameters indicates the possibility of using a capillary rheometer to determine the appropriate hydration level of ingredient formulations before extruding with a pasta press.     

Viscoelastic Properties of Extruded Cereal Melts

Hydrophilic biopolymer systems reach a state of maximum plasticization at a concentration of water designated as W_g′. The thermomechanical behaviour of various extruded cereals were investigated at concentrations above and below W_g′ to determine the significance of W_g′ on the viscoelastic properties in the rubbery region above T_g. Cereal melts were produced via extrusion cooking using a twin-screw extruder at in-barrel moisture contents ranging from 25 to 42% (wb). Dynamic mechanical thermal analysis (DMTA) was used to determine the viscoelastic properties for melts obtained from degermed corn meal, oat flour, pregelatinized corn starch and pregelatinized waxy maize. All of the extruded melts displayed reductions in the storage modulus of about two orders of magnitude from the glassy to rubbery regimes. At temperatures greater than 320K, another transition is apparent for extruded oat flour. These losses may be attributed to a reduction in physical crosslinks and/or entanglements. With respect to the other melts investigated, differences in the oat flour melts at temperatures above T_gmay be due to the increased presence of protein and lipid. Given the apparent partly crystalline nature of these melts at moisture contents <W_g′, the most appropriate representation of the viscoelastic properties may be isotimic plots of the viscoelastic functions. These contour plots provide a more comprehensive guide to material behaviour than the ‘traditional’ state diagrams found throughout the literature. An important point is that prediction of viscoelastic properties above T_gfor polymers where the internal structure changes with temperature or moisture content, cannot be predicted using the same methods of reduced variables as for amorphous polymers. Thus rather than using these methods, experimental data, such as given here, may prove to be necessary to design or understand processes involving cereal melts based on their viscoelastic properties.     

淀粉老化调控对燕麦全粉挤压面条蒸煮品质的影响

燕麦粉不含面筋蛋白,使燕麦全粉面条煮熟后易浑汤、蒸煮损失率大,目前只能温水浸泡复水食用,是限制燕麦更广泛推广的难题之一。为了满足市场对燕麦全粉面条的需求,以利用二级挤压技术生产的燕麦全粉挤压面条为试材,对成型面条进行了调湿老化、蒸制老化及冷冻老化处理,比较了不同老化方式对燕麦全粉挤压面条蒸煮品质的影响。结果表明,调湿老化处理的面条蒸煮损失率最小(2.26%~3.34%),蒸制老化次之(4.19%~5.19%),冷冻老化最大(5.16%~7.97%)。不同老化处理的面条感官评分差异不显著,以调湿老化处理24h的面条感官评分最高(87.2分);调湿老化处理面条的淀粉相对结晶度(12.47%~16.10%)、热焓值(1.044 0~1.056 0J·g-1)及回生值(519.5~558.0cP)均最大,蒸制老化次之,冷冻老化最小。综合分析可知,对燕麦挤压面条进行淀粉老化处理,能够显著降低燕麦全粉挤压面条的蒸煮损失率,最优方式为调湿老化24h。     

Quality evaluation of commercial chile-based salsas

A standardized extrusion cooking process was developed for production of a high protein weaning food based on peanuts, maize and soybeans. Major factors evaluated included the effects of blend formulation, extrusion temperature and feed moisture content on ease of extrusion and product quality characteristics. Results showed bulk density and hardness increased while expansion index decreased with increase in feed moisture content. At a fixed range of feed moisture content, product bulk density and firmness decreased while expansion index increased with increasing extrusion temperature. For ease of extrusion and best product quality in terms of sensory attributes and cooking properties, the following extrusion parameters were established for a blend formulation of 75% maize, 10% peanut and 15% soybean: feed particle size of 300–400 m extruded using a screw speed of 500 rpm, with a feed rate of 4.6 kg/min, feed moisture content of 16–18%, and extrusion temperature of 100 ,°C–105,°C. Pair-wise comparison of the sensory attributes of porridges prepared from milled samples of the weaning foods showed significant differences between extruded products and existing traditional counterparts, with very high scores for all sensory attributes of the extruded products, especially extruded raw (non-roasted) blend samples. In the Home-Use-Test, at least 92% of respondents in two out of the three major ecological zones of Ghana placed overall sensory and functional characteristics of extruded raw blend samples as highly acceptable. About 7% of respondents scored sensory and functional quality attributes as acceptable.     

Production of nixtamalized flour and tortillas from amarantin transgenic maize lime-cooked in a thermoplastic extruder

The potential use of quality protein transgenic maize (genetically modified maize with the cDNA of amarantin) for preparation of flour and tortillas through an extrusion lime cooking process was investigated. Tortillas from extruded transgenic maize flour had similar physicochemical and sensory properties than those from the commercial brand MASECA™; however, the former had the highest (P < 0.05) protein content (12.91 vs 8.93%, db), essential amino acids content, calculated protein efficiency ratio (C-PER; 2.27 vs 0.90) and protein digestibility corrected amino acid score (PDCAAS; 55.54 vs 30.18%) and therefore they were nutritionally better. The use of transgenic maize for flour and tortilla preparation through an extrusion lime cooking process may have a positive impact on the nutritional status of people from countries where maize is the basic staple food. It also represents an alternative process to nixtamalization that requires little energy and water, it does not generate wastewater, and all components of the maize kernel are retained.     

An innovative approach for significantly increasing enzyme resistant starch type 3 content in high amylose starches by using extrusion cooking

In this study effects of extrusion cooking on enzyme resistant starch (RS) formation in high amylose corn starches (Hylon V and VII) and the functional properties of RS preparations were investigated. Native starches were extruded at 50, 60, 70% feed moisture contents, at constant screw speed (100 rpm) and barrel temperature (140 °C). Among these samples, the highest RS contents were observed at 60% feed moisture. Therefore, feed moisture in the second and third extrusion cycles was set at 60%. There were significant increases in RS contents of both Hylon V and Hylon VII after the second extrusion cycle (p < 0.05). After the third extrusion, the RS levels reached to 40.0 and 45.1% for Hylon V and Hylon VII, respectively. Substantial loss of birefringence in these samples indicated that the increases in RS were mainly due to RS3 formation. The RS samples produced by extrusion did not have high emulsion capacity, but the ones produced from Hylon VII had high emulsion stability. Although, decreases in L* and increases in b* values of extruded samples were significant as compared to respective native starches, the changes were not substantial. Therefore, their incorporation is not expected to cause major changes in the colour of end-products.     

Fabrication and characterization of oat flour processed by different methods

The properties of oat flour can be manipulated by processing to suit various consumption and product development needs. In this work, three different processes typically used on oat flour, namely the extrusion, drum drying and enzyme-treatment spray drying process were evaluated with respect to how each process changes the quality of the oat flour. Results showed that the extrusion process produced oat flour with the best flow ability while the enzyme-treated spray drying process led to the lowest flowability. The color of enzyme-treated spray-drying oat flour was the brightest while the oat flours turned darker after extrusion and drum drying. In addition, drum dried oat flour had the highest capability to hold water. In terms of particle size distribution, the extruded and drum dried oat flour showed smaller particle size and the particle had less complete and irregular surfaces. On the other hand, the enzyme-treated spray-drying samples showed the best particle uniformity and sphericity. The viscosity of all the treated oat flour decreased with increasing shear rate, indicating the shear thinning behavior, and a weak gel-like behavior with very high viscosity was obtained via drum drying. The results reported here can be useful and provide a baseline to fully understand how the oat flour properties changes with different processing methods to offer a wider opportunity in using oat flour for food product fortification and design.     

Physicochemical, Structural and Textural Properties of Tortillas from Extruded Instant Corn Flour Supplemented with Various Types of Corn Lipids

The chemical composition and the components of corn grain affect the quality of tortillas produced from extruded instant corn flour (EICF). We have studied the effects of various types of corn lipids added at several concentrations to the regular raw corn flour before processing. The structural properties of flour, the effective moisture diffusion coefficient and the weight loss during cooking of fresh masa, as well as the textural characteristics of tortillas were analysed as a function of concentration and type of corn lipid added. The concentration of added lipid ranged from 0·5 to 2% (w/w). Each type and concentration of lipid was observed to have a different effect in the quality of masas and tortillas. Commercially it is desired to have tortillas with good properties and a high yield, that is, optimum weight transformation from corn to tortilla. From our analysis, the lowest dehydration rate (lowest effective moisture diffusion coefficient) and the best physicochemical and textural characteristics of fresh masas and tortillas were obtained from flour supplemented with 0·5% (w/w) of the nonpolar lipid fraction III. The loss in starch crystallinity due to the cooking process of masa into tortilla was similar in all treatments.     

Effects of selected extrusion parameters on physicochemical properties and in vitro starch digestibility and β-glucan extractability of whole grain oats

Whole grain oat flour was extruded under different moisture contents (15%, 18%, 21%), barrel temperatures (100 °C, 130 °C), and screw speeds (160 rpm, 300 rpm, 450 rpm), and selected physicochemical properties, in vitro starch digestibility, and β-glucan extractability of the extrudates were analyzed. An increase in screw speed resulted in an increase in radial expansion index, water absorption index, and water solubility index. Screw speed significantly affected slowly and rapidly digestible starch. Moderate screw speed (300 rpm) led to higher slowly digestible starch with an accompanying decrease in rapidly digestible starch. Low moisture conditions (15%) resulted in the highest resistant starch and water-extractable β-glucan. Under the conditions used in this study, extrusion did not result in changes in water-extractable β-glucan molecular weight. Thus, extrusion might be beneficial in improving functionality and consumer acceptability by affecting physicochemical properties, in vitro starch digestibility, and β-glucan extractability of oat extrudates.     

Certain functional properties of defatted pumpkin seed flour

Defatted pumpkin (C. pepo andC. maxima) seed flour has potential food uses because of its high protein content, 61.4±2.56%. The functional and electrophoretic properties of the defatted flour were investigated. Polyacrylamide gel electrophoresis and electrofocusing indicated 14 bands of water-soluble protein subunits with isoelectric points between 3.81–8.08 and apparent molecular weights between 19,200 and 97,000 daltons. Minimum nitrogen solubility was observed at pH values between 3.0–7.0 and exceeded 90% at pH above 9.0. Solubility was a function of ionic strength. It appeared that, even at the pH of minimum solubility, the pumpkin seed proteins could be dissolved up to high concentrations by increasing NaCl molarity. The viscosity of flour-water dispersion was affected by flour and salt concentrations, and temperature. The least gelation concentration was 8% (w/v) and the water and oil absorption 24.8±2.03 and 84.4±4.05 g/100 g respectively. Sorption isotherms, BET monolayer moisture and binding energy of sorption were also calculated. Both foam capacity and stability were pH dependent.     

Extrusion processing characteristics of quinoa (Chenopodium quinoa Willd.) var. Cherry Vanilla

Extrusion processing characteristics of Cherry Vanilla quinoa flour (Chenopodium quinoa Willd) were investigated using a three factor response surface design to assess the impact of feed moisture, temperature, and screw speed on the physicochemical properties of quinoa extrudates. Specific mechanical energy (SME) required to extrude this quinoa variety was higher (250–500 kJ/kg) than previously reported for quinoa. The following characteristics of the extrudates were observed: expansion ratio (1.17–1.55 g/cm³), unit density (0.45–1.02 g/cm³), water absorption index (WAI) (2.33–3.05 g/g), and water solubility index (WSI) (14.5–15.87%). This quinoa flour had relatively low direct expansion compared to cereal grains such as corn or wheat, suggesting that it is not well suited for the making of direct expanded products. The study further suggests that there is a need to understand the processing characteristics of new quinoa varieties for cultivation. Understanding extrusion and other quality traits in advance will help to select the appropriate varieties that would allow food processors to meet consumer needs.     

Thermomechanical Glass Transition of Extruded Cereal Melts

Cereal melts were produced via extrusion cooking using a twin-screw extruder at in-barrel moisture contents ranging from 25 to 42% (wb). Dynamic mechanical thermal analysis was performed to determine the plasticizing effect of water on the glass transition (T_g) for melts obtained from degermed corn meal, oat flour, pregelatinized corn starch and pregelatinized waxy maize. For degermed corn meal, T_gwas found to decrease with increasing water contents up to about 30% (wb). Above 30% moisture content, T_gwas found to be essentially constant and approximately equal to 270K. Thus, W_g′ was estimated to be 30% moisture content. For samples of moisture content less than W_g′, loss tangent vs. temperature plots in the glass transition region were observed to be broader and of smaller amplitude than those above W_g. Glass transitions ranged from 270 to 321K for sample moisture contents ranging from 36·3 to 22·2% (wb), respectively. For an oat flour, T_gvalues ranging from 270 to 303K were observed for moisture contents of 39·2 to 26·1% (wb), respectively. Melts formed from pregelatinized corn starch and pregelatinized waxy maize had glass transitions similar to corn meal at a similar moisture content of 27%. The significance of these results, in terms of extrusion cooking of cereals, is discussed in this work.