Selected Functional Properties of Extruded Starch Acetate and Natural Fibers Foams

Response surface methodology was employed to study the functional properties of starch acetate foams blended with 0, 7.5, and 15% wood, oat, and cellulose fibers. The blends were extruded with 14, 17, and 20% ethanol as a blowing agent, using a twin‐screw extruder with 160°C barrel temperature and 225 rpm screw speed. Physical characteristics of the extrudates including radial expansion ratio, unit density, and bulk density; and mechanical properties including unit spring index and bulk spring index were determined. Scanning electron micrographs were taken to observe foam cell textures. Higher fiber content resulted in lower radial expansion. Ethanol content had a positive effect on foam expansion. Higher expansion was obtained in starch acetate‐cellulose foams because better starch acetate‐fiber matrix was formed. Mechanical properties increased with higher fiber and ethanol contents. Micrographs showed that uniform cell structures were associated with better mechanical properties.     

Effect of Free Fatty Acids Addition on Corn Grits Extrusion Cooking

The influence of added fatty acids on extrusion cooking of corn grits and extrudate properties was studied. Samples with three average corn grits particle sizes were processed in a twin-screw extruder; fatty acids content (0.2–0.8%, wb) varied, and experimental conditions were kept constant (moisture content 18.4% wb, barrel temperature 150°C, screw speed 165 rpm). The effect of adding fatty acids was studied by analyzing water solubility and absorption indices, expansion indices, and mechanical (puncture test) and structural (computerized image analysis) extrudate properties. When fatty acids were added, water solubility and absorption indices decreased, radial expansion index decreased, longitudinal expansion index increased, number of cells increased, and mechanical resistance of extrudates decreased. The influence of added fatty acids was attributed to the formation of fatty acids-amylose complexes.     

Extrusion Expansion Characteristics of Samples of Select Varieties of Whole Yellow and Green Dry Pea Flours

Extrusion expansion characteristics of commercially available whole flours from three green pea varieties (Ariel, Aragorn, and Daytona) and three yellow pea varieties (Carousel, Treasure, and Jetset) were investigated with a corotating twin‐screw extruder. Feed moisture content was kept constant at 15 ± 0.5% (wb). Two barrel temperature levels of 140 and 160°C and three screw speed levels of 150, 200, and 250 rpm were studied. A round die with an opening of 3 mm was used. The radial expansion ratio (ER) of whole pea extrudates was 2.75–3.34. It was shown that the varieties had a significant impact on the expansion properties. Daytona green pea had a significantly greater ER compared with all other varieties (P < 0.05) within the conditions studied. ER was also found to have a positive linear correlation with screw speed. The microstructure of extrudate cross‐sections showed that the samples with greater expansion had more uniform and relatively small pore structure. The results show the importance of using the specific varieties of peas for optimum expansion during extrusion.     

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.     

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.     

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.     

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 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.     

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.     

Extrusion of Wheat Gluten Plasticized with Glycerol: Influence of Process Conditions on Flow Behavior,Rheological Properties,and Molecular Size Distribution

Gluten-glycerol dough was extruded under a variety of processing conditions using a corotating self-wiping twin-screw extruder. Influence of feed rate, screw speed, and barrel temperature on processing parameters (die pressure, product temperature, residence time, specific energy) were examined. Use of flow modeling was successful for describing the evolution of the main flow parameters during processing. Rheological properties of extruded samples exhibited network-like behavior and were characterized and modeled by Cole-Cole distributions. Changes in molecular sizes of proteins during extrusion were measured by chromatography and appeared to be correlated to molecular size between network strands, as derived from the rheological properties of the materials obtained. Depending on operating conditions, extrudates presented very different surface aspects, ranging from very smooth-surfaced extrudates with high swell to completely broken extrudates. The results indicated that extrudate breakup was caused by increasing network density, and some gliadins may have acted as cross-linking agents. Increasing network density resulted in decreasing mobility of polymeric chains, and “protein melt” may no longer have been able to support the strain experienced during extrusion through the die. Increasing network density was reflected in increased plateau modulus and molecular size of protein aggregates. Increasing network structure appeared to be induced by the severity of the thermomechanical treatment, as indicated by specific mechanical energy input and maximum temperature reached.     

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.     

Experimental Determination of Longitudinal Expansion During Extrusion of Starches

Expansion during extrusion of starches is a unique phenomenon used extensively in the food industry. Sectional expansion index is usually determined as the ratio of the square of the diameter of the final extrudate to the square of diameter of the die through which the product is expelled. Longitudinal expansion index is calculated indirectly by doing a mass balance across the extruder and making an assumption for density of the dough melt in the die. The objective of this research was to determine the longitudinal expansion index experimentally using a die designed to measure the velocity of the melt dough inside the die. A tracer was induced to change the conductivity of the melt dough. The velocity inside the die was then determined by measuring the time of travel of a tracer with the help of electrical probes. Corn starch (25% amylose and 30% moisture content) was extruded in a twin-screw extruder at a barrel temperature of 140°C, screw speeds of 80, 120, and 160 rpm, and feed rates corresponding to the screw speeds varying from 7.35 to 13. 35 kg/hr. An inverse relationship was observed between the longitudinal expansion and the sectional expansion indices.     

Flavor Retention in Pregelatinized and Internally Flavored Starch Extrudates

Corn starch (25% amylose content) was pregelatinized in a twin-screw extruder. The extrudate was ground and reextruded after adjusting moisture content to 9, 13, or 17% (db) and blending with 5% (w/w) of flavor compounds cinnamaldehyde, eugenol, nonanoic acid, or 3-octanone. Initial moisture content significantly influenced radial expansion, specific mechanical energy, and flavor retention. Significantly higher flavor retention was obtained when flavor was injected into the extruder barrel as compared to preblending of flavors in pregelatinized starch. Flavor retention upon extrusion was lower with pregelatinized starch than with raw starch.     

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.     

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.     

Twin‐Screw Extrusion Processing of Rainbow Trout (Oncorhynchus mykiss) Feeds Using Various Levels of Corn‐Based Distillers Dried Grains with Solubles (DDGS)

Increasing demand for seafood products and rising demand for fish meal for commercial fish feeds is driving the search for effective alternative protein sources. Twin‐screw extrusion trials were conducted to study the production of nutritionally balanced feeds for rainbow trout fingerlings (Oncorhynchus mykiss). Six isocaloric (≈4.61 kcal/g) ingredient blends with a target protein content of >45% db were formulated with 0, 10, 20, 30, 40, and 50% distillers dried grains with solubles (DDGS) and other feed ingredients. The moisture contents of the diets were initially adjusted to 5–7% db, and then extruded at 250 rpm using dual 1.9 mm dies with varying amounts of steam (7.2–7.7 kg/hr) injected into the conditioner and water (4.3–6.5 kg/hr) into the extruder. Mass flow rates, moisture contents, and temperatures were measured during processing and moisture content, water activity, unit density, bulk density, expansion ratio, compressive strength, compressive modulus, pellet durability index, water stability, and color were analyzed to quantify the effects of varying DDGS content on the extrudate physical properties. Significant differences (P < 0.05) among the blends were observed for color and bulk density for both the raw and extruded materials, respectively, and for the unit density and pellet durability index of the extruded products. There were also significant changes in redness and yellowness, but only minor changes in brightness, among the final products with increasing DDGS content. The compressive strength of the extrudates increased significantly with increasing DDGS. Expansion ratio of all pellets was low. All extruded diets achieved very good water stability.     

Effect of Particle Size and Moisture Content on Viscosity of Fish Feed

A model was developed for the influence of particle size on the extrusion of a fish feed and the physical characteristics of the extrudates evaluated. The study was conducted using factorial experiments in a fractional replication design for four variables with three levels, and one‐third of the replicates (3⁴ factorial in 27 units) were examined in a laboratory extruder. The torque‐screw speed measurement was used to develop a viscosity model equation that considered different shear rates, product temperature, initial moisture content, and particle size. When particle size decreased, the apparent viscosity became smaller. The barrel pressure was important in producing extrudate with a uniform volume over the range of processing conditions tested because it had a strong correlation with the volumetric expansion. The material with lower moisture and larger particles caused the specific mechanical energy to increase. The viscosity model developed in this study can be applied to the development of large‐scale extrusion models that determine the effect of particle size on the feed material extrudates.     

Effects of Extruder Screw Speeds on Physical Properties and In Vitro Starch Hydrolysis of Precooked Pinto,Navy, Red,and Black Bean Extrudates

Precooked pinto, navy, red, and black bean flours were extruded at different screw speeds (320, 380, and 440 rpm) with a twin‐screw extruder. Effect of speed on physical properties and in vitro starch hydrolysis was investigated. Increasing screw speeds reduced water activity, expansion index, and texture. Extrudates could not be obtained from pinto bean flour at 440 rpm because of the high shear effect. Water absorption index and water solubility index were not significantly affected by screw speed but were significantly higher than for unextruded precooked flour. A significant change in color was observed in navy beans, characterized by increasing b values on the Hunter color scale. Resistant starch ranged from 3.65 to 4.83% db and was not significantly affected by screw speed. Glycemic index of all extrudates was high, ranging from 81.3 to 86.9.     

Effects of Processing Parameters on Physical Properties of Corn Starch Extrudates Expanded Using Supercritical CO2 Injection

Corn starch was extruded with a corotating twin-screw extruder (24:1 L/D ratio, 31-mm screw diameter) and supercritical CO₂ was injected as a blowing agent. The effects of barrel temperature (80–90°C), screw speed (150–250 rpm), and water injection (30–54 g/min) on specific mechanical energy (SME) input for the process and the physical properties of extrudates, such as expansion ratio, water absorption (WA), water solubility (WS), breaking stress, and elastic modulus, were examined using a response surface methodology. Barrel temperature had the greatest effect on physical properties of extrudates but not on SME input, whereas screw speed and water injection had significant effects on SME input. Extrudates had a smooth surface, and air cells were uniform and closed, providing low WA and WS. Using superimposed contour plots, optimum barrel temperature, screw speed, and water injection rate, based on maximum expansion ratio and minimum SME input, were 94–96°C, 155–175 rpm, and 36–39 g/min, respectively.     

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.