Effect of ambient conditions on dimensional stability and stiffness of commercial paperboard and paperboard trays

The objective of this study was to develop laboratory test methods for characterizing the effects of changed moisture content on paperboard trays produced by press-forming process. Influence of moisture on the properties of unconverted paperboard such as bending stiffness, bursting strength, and curling was studied. Paperboard and tray samples were tested after storing in different relative humidity conditions (35, 50, 65, 80 and 95% RH). The effect of PE and PET extrusion coatings on these properties was also studied. It was found that increase in moisture content of paperboard decreases bending and bursting strength, dimensional stability and stiffness of paperboard trays. Such physical and mechanical properties as bending stiffness and curling of paperboard seem to define the stiffness of ready-made trays and their dimensional stability. Paperboards and trays with extruded PE and PET one sided coatings demonstrated higher strength properties but at the same time had lower dimensional stability comparing to uncoated paperboards. Samples with smaller polymer coat weight had better dimensional stability than respective samples with higher coat weight. It was also found that preconditioning of paperboard in lower humidity environment before press-forming could improve dimensional stability and stiffness of ready-made tray.

Development and assessment of acceptability and nutritional properties of a light snack

A light snack was developed using a fat replacer as a flavor fixative agent. The product presented a calorie reduction of up to 47.5% in comparison with products available on the market. The impact of this fat replacer on the sensory properties was determined by comparing this light snack to the traditional ones. No significant difference in texture was observed; however, there was a difference in color (deltaE = 8.67), due mainly to luminosity (deltaL = 7.79). The light snack presented high sensory acceptability (7.27 ± 1.3; 82.5% of grades were > 7 on 9-point hedonic scale); no significant difference in snack acceptability was observed. However, the traditional snack was significantly preferred in sensory terms (p < 0.05). In an opinion survey when the consumers were informed about snack composition, 75% of them said that they would buy the light snack instead of the traditional one. The caloric and fat reductions allow the use of the claims "light snack" and "fat free", in accordance with the legislation of various countries. We conclude that it is technologically possible to use a fat replacer in snack production, resulting in a sensory acceptable light snack with great potential to replace traditional ones.

The effects of water and sucrose contents on the physicochemical properties of non-directly expanded rice flour extrudates

Rice flour was processed by extrusion cooking in the presence of variable contents of water and sucrose. The process was carried out in a twin-screw extruder under the conditions given by a centre rotational experimental design of second order. The effects of the independent variables, water content (27.9 to 42.1%), and sucrose content (0.1 to 19.9%) on the physicochemical properties of the extrudates were investigated. The water absorption index (WAI), water solubility index (WSI), volumetric expansion index (VEI), and bulk density (BD) were determined as dependent variables. BD was determined for samples before and after frying. An increase in water contents resulted in higher WAI and VEI, and lower WSI and BD for extrudates before and after frying. Higher sucrose levels led to increased values of WAI and VEI and to reduced values of WSI and BD. Both independent variables had significant influence on the physicochemical properties of rice flour extrudates. However, the sucrose content was the most significant. The interaction between these two independent variables and their quadratic effect were also important for the responses studied.

Effect of sugar and water contents on non-expanded cassava flour extrudates

The effects of sucrose and water contents on cassava flour processed by extrusion at varied concentrations of sucrose (0-20% w/w) and water (28-42% w/w) were studied by applying response surface methodology. The extrusion of the mixtures was performed in a twin screw extruder fitted to a torque rheometer. The specific mechanical energy (SME) dissipated inside a conical twin-screw extruder was measured. Water absorption index (WAI), water solubility index (WSI) and paste viscosity readings (cold viscosity (CV), peak viscosity (PV), breakdown (BD) and set back (SB)) during a gelatinization-retrogradation cycle measured in a Rapid Visco Analyzer were determined on non-directly extruded products. The results indicated that SME and WSI decreased as a function of water and sucrose contents. WAI and pasting properties were influenced by water content. A non antiplasticizing effect of the sucrose content was observed on pasting properties, suggesting that sucrose did not reduce the availability of water available for gelatinizing cassava flour during the extrusion process. The nature of the optimum point was characterized as a saddle point for WAI, WSI, PV and BD, whereas SME showed a maximum and CV and SB a minimum. The results indicated to be valuable for the production of non-expanded cassava flour extrudates with desirable functional properties for specific end users.

Calcium bioavailability of raw and extruded amaranth grains

Calcium bioavailability of raw and extruded amaranth grains was assessed in a biological assay in rats. Rats were fed for 28 days on diets in which raw or extruded amaranth was the only calcium source, compared to a control diet with calcium carbonate. Calcium and phosphorous levels were determined in the rats' serum during the experimental period and in the bones at the end of the experiment. Amaranth extrusion increased its calcium bioavailability, assessed by tibia and femur weights and calcium and phosphorous content of the bones. Apparent calcium absorption index, the force needed to break the bones and bone densitometry of both extruded and raw amaranth were the same, though different from the control group. The results show that amaranth can be a complementary source of dietary calcium the bioavailability of which is favorably modified by the extrusion process.

Determination of thermobacteriological parameters and size of Bacillus stearothermophilus ATCC 7953 spores

In order to determine thermobacteriological parameters for B. stearothermophilus spores, they were diluted in a saline solution medium and in ground corn-soybean mix, distributed in TDT tube, and submitted to heat for a specific period of time. The D value (time to reduce 1 log cycle of microbial count under a certain temperature) and z value (variation of temperature to cause 10-fold change in D value) were estimated. To estimate their dimensions, the spores were visualized by using a scanning electron microscope. D121.1 ºC and z values for these spores, as determined in the saline solution, were 8.8 minutes and 12.8 ºC, respectively. D121,1 ºC and z values determined in the corn-soy mix were 14.2 minutes and 23.7 ºC, respectively. The micrographs indicated that the spores have homogeneous shape and size, with length and diameter of 2 and 1 µm, respectively. These results confirm that the spore is highly thermal-resistant, and it is a good biological indicator to evaluate the extrusion process as a feed sterilizer.

Quinoa (Chenopodium quinoa, Willd.) as a source of dietary fiber and other functional components

Four varieties of an Andean indigenous crop, quinoa (Chenopodium quinoa Willd.), were evaluated as a source of dietary fiber, phenolic compounds and antioxidant activity. The crops were processed by extrusion-cooking and the final products were analyzed to determine the dietary fiber, total polyphenols, radical scavenging activity, and in vitro digestibility of starch and protein. There were no significant differences in the contents of total dietary fiber between varieties of quinoa. In all cases, the contents of total and insoluble dietary fiber decreased during the extrusion process. At the same time, the content of soluble dietary fiber increased. The content of total phenolic compounds and the radical scavenging activity increased during the extrusion process in the case of all 4 varieties. There were significant differences between the varieties and the content of total polyphenols. The in vitro protein digestibility of quinoa varieties was between 76.3 and 80.5% and the in vitro starch digestibility was between 65.1 and 68.7%. Our study demonstrates that quinoa can be considered a good source of dietary fiber, polyphenols and other antioxidant compounds and that extrusion improves the nutritional value.

Modified broken rice starch as fat substitute in sausages

The demand for low-fat beef products has led the food industry to use fat substitutes such as modified starch. About 14% of broken rice is generated during processing. Nevertheless, this by-product contains high levels of starch; being therefore, great raw material for fat substitution. This study evaluated the applicability of chemically and physically modified broken rice starch as fat substitute in sausages. Extruded and phosphorylated broken rice was used in low-fat sausage formulation. All low-fat sausages presented about 55% reduction in the fat content and around 28% reduction in the total caloric value. Fat replacement with phosphorylated and extruded broken rice starch increased the texture acceptability of low-fat sausages, when compared to low-fat sausages with no modified broken rice. Results suggest that modified broken rice can be used as fat substitute in sausage formulations, yielding lower caloric value products with acceptable sensory characteristics.

Some functional characteristics of extruded blends of fiber from sugarcane bagasse, whey protein concentrate, and corn starch

Blends of fiber from sugar cane bagasse, corn starch, and whey protein concentrate were extruded. A single screw extruder, equipped with a screw at a constant compression ratio of 1:1 and a die diameter of 3 mm, was used. The best processing conditions were determined according to a central composite rotatable design (α = 1.41) with 5 central points, which gives a total of 13 tests. During the extrusion process the content of insoluble fiber decreased and that of soluble fiber increased. An increase in the contents of fiber and in the barrel temperature resulted in a decrease in the expansion index values and an increase in the water absorption index values; whereas in blends with intermediate fiber contents the effects in these parameters were found to be the opposite. High fiber contents increased penetration force but decreased luminosity, water solubility index values and the adhesive force in gels. The extrusion process improved the functional properties of sugarcane fiber bagasse enabling its addition to diverse alimentary systems.

Changes in physical properties of extruded sour cassava starch and quinoa flour blend snacks

Given the broad acceptance of sour cassava starch biscuits in Brazil and the nutritional quality of quinoa flour, this study aimed to evaluate the effect of extrusion temperature, screw speed, moisture, and amount of quinoa flour on the physical properties of puffed snacks. Extrusion process was carried out using a single-screw extruder in a factorial central composite design with four factors. Effects of moisture and amount of quinoa flour on the expansion index and specific volume of snacks were observed. There was a pronounced increase in water solubility index of blends with the extrusion process with significant effects of all process parameters on the WSI. Higher water absorption index (WAI) was observed under high temperature, low moisture, and lower quinoa flour amount. Temperature and amount of quinoa flour influenced the color of the snacks. A positive quadratic effect of quinoa flour on hardness of products was observed. Blends of sour cassava starch and quinoa flour have good potential for use as raw material in production of extruded snacks with good physical properties.

Effect of adding unconventional raw materials on the technological properties of rice fresh pasta

The aim of this study was to develop fettuccini type rice fresh pasta by cold extrusion. To produce the pasta, a 2² Central Composite Rotational Design was used, in which the effects of the addition of pre-gelatinized rice flour - PGRF (0-60%) and modified egg albumin - MEA (0-10%) were studied. The dependent variables were the results of the cooking test and of the instrumental texture. The optimum cooking time for all of the formulations of rice fresh pasta was 3 minutes. MEA had a greater effect on increasing the weight of the pasta when compared to that of PGRF. It was found that with the addition of PGRF increase in loss of solids in cooking water, whereas MEA exerted the opposite effect on this parameter. Moreover, the maximum value of MEA (10%) had an optimum effect on pasta firmness, while PGRF had a negative effect on this parameter. The maximum values of PGRF and MEA reduced the stickiness of the pasta. Based on these results and on the parameters considered as most important, the rice pasta with the best technological characteristics was that with the maximum levels of MEA (10%) and no addition of PGRF (0%). This product was submitted to sensory and microbiological analyses, with good results.

The kinetics of lipase activity and hydrolytic rancidity of raw, parboiled, and extruded rice bran during storage

The main problem related to rice bran use is that it goes rancid right after its production. The objective of the present study was to apply a mathematical model to evaluate the kinetics of the lipase activity and hydrolytic rancidity of the raw rice bran (RRB), extruded rice bran (ERB), and parboiled rice bran (PRB) stored in low density polyethylene bags at room temperature for 180 days. Extrusion and parboiling were efficient in preventing free fatty acid formationin ERB and PRB.Extrusion reduced the velocity constant of lipase activity as compared to that of RRB while parboiling increased it, and both decreased the lipase activity after equilibrium from 150 days. The extrusion and parboiling treatments increased the velocity constants for the liberation of free fatty acids although the equilibrium was reached with reduced production of free fatty acids in relation to the production of raw rice bran after 150 days ofstorage. Extrusion proved the best treatment under the storage temperature conditions of rice bran from cultivar BRS Primavera.

Effects of processing on physical properties of extruded snacks with blends of sour cassava starch and flaxseed flour

The opportunity to supplement common cassava biscuits with a product of higher nutritional value meets consumer expectations. In this work it was studied the effects of process parameters and flaxseed addition on physical properties of expanded snacks. Extrusion process was carried out using a single screw extruder in a factorial central composite rotatable design with four factors: flaxseed flour percentage (0-20%), moisture (12-20%), extrusion temperature (90-130 °C) and screw speed (190-270). The effect of extrusion variables was investigated in terms of expansion index, specific volume, water absorption index, water solubility index, color parameters (L*, a* ,b*) and hardness. The data analysis showed that variable parameters of the extrusion process and flaxseed flour affected physical properties of puffed snacks. Among the experimental conditions used in the present study, expanded snack products with good physical properties can be obtained under the conditions of 10% flaxseed flour, 230 rpm screw speed, temperature of 90 °C and moisture of 12%.

Characterization of new sources of derivative starches as wall materials of essential oil by spray drying

Starch derivatives of taro (Colocasia esculenta L. Schott) and rice were characterized as wall materials of orange oil (d-limonene) by spray drying. Native starches were initially hydrolyzed with HCl and then esterified. Succinylated starches were modified using a conventional method in a slurry and were extruded; whereas, the phosphorylated starches were modified using the extrusion process. Viscosity and solubility of starches reduced after acid hydrolysis, derivatization, and extrusion. The particle size of the wall materials ranged between 20.05 and 31.81 µm. The encapsulation efficiency of the phosphorylated taro, rice, and waxy corn starches was 96.9, 96.8 and 97.1% respectively, and 98.6, 98.1, and 98.8% for succynilated taro, rice, and waxy corn starches, respectively. Starch derivatives of taro and rice could potentially be used as wall materials of orange oil d-limonene.

Effect of different calcium sources on the antioxidant stability of tortilla chips from extruded and nixtamalized blue corn (Zea mays L.) flours

This research aimed to develop tortilla chips (TC) high in antioxidants from extruded and nixtamalized blue corn flours prepared with calcium hydroxide Ca(OH)2 and calcium lactate C6H10O6Ca. Tortilla chips were made with extruded flours [0.1% Ca(OH)2; 0.9% C6H10O6Ca; without calcium] and nixtamalized flours [1% Ca(OH)2; 2.95% C6H10O6Ca] using the frying process. Total anthocyanin, total phenolics content, antioxidant activity, color, texture, and oil content were determined. The color of tortilla chips from extruded flours (TCEF) showed high values of the parameters a* and b* indicating a reduction in the blue color. These color parameters were significantly different from those observed in tortilla chips from nixtamalized flours (TCNF), which tended to be more blue. The TCEF retained 15% anthocyanins, 34% phenolics, and 54% antioxidant activity. Pearson's correlation analysis indicated that anthocyanins and phenolics correlated significantly with antioxidant activity and color. TCEF with both calcium sources showed higher fracturability compared with that of TCNF. Oil absorption showed an opposite effect, with lower oil content in TCEF. Nixtamalization and extrusion with C6H10O6Ca resulted in flours and TC high in anthocyanins and antioxidant activity, representing an alternative production process for corn snack high in antioxidants.