Flavour retention during high temperature short time extrusion cooking process: a review

Research on the stability of flavours during high temperature extrusion cooking is reviewed. The important factors that affect flavour and aroma retention during the process of extrusion are illustrated. A substantial number of flavour volatiles which are incorporated prior to extrusion are normally lost during expansion, this is because of steam distillation. Therefore, a general practice has been to introduce a flavour mix after the extrusion process. This extra operation requires a binding agent (normally oil), and may also result in a non-uniform distribution of the flavour and low oxidative stability of the flavours exposed on the surface. Therefore, the importance of encapsulated flavours, particularly the beta -cyclodextrin-flavour complex, is highlighted in this paper.

Sensory and instrumental analyses of volatiles generated during the extrusion cooking of oat flours

Three batches of oats were extruded under four combinations of process temperature (150 or 180 °C) and process moisture (14.5 and 18%). Two of the extrudates were evaluated by a sensory panel, and three were analyzed by GC-MS. Maillard reaction products, such as pyrazines, pyrroles, furans, and sulfur-containing compounds, were found in the most severely processed extrudates (high-temperature, low-moisture). These extrudates were also described by the assessors as having toasted cereal attributes. Lipid degradation products, such as alkanals, 2-alkenals, and 2,4-alkadienals, were found at much higher levels in the extrudates of the oat flour that had been debranned. It contained lower protein and fiber levels than the others and showed increased lipase activity. Extrudates from these samples also had significantly lower levels of Maillard reaction products that correlated, in the sensory analysis, with terms such as stale oil and oatmeal. Linoleic acid was added to a fourth oat flour to simulate the result of increased lipase activity, and GC-MS analysis showed both an increase in lipid degradation products and a decrease in Maillard reaction products.

OPTIMIZATION OF EXTRUSION COOKING PROCESS FOR CHICKPEA (CICER-ARIETINUM, L) DEFATTED FLOUR BY RESPONSE-SURFACE METHODOLOGY

Response surface methodology was employed to optimize the production of a snack food from chickpea. The independent variables, process temperature (123-137-degrees-C) and feed moisture (13-27% d.s.b.) were selected at five levels (rotatable five level composite design: - square-root 2, -1, 0, 1, + square-root 2) in the extrusion of defatted chickpea flour. Response variables were expansion ratio, shear strength of the extrudate and sensory preference assessed by an untrained panel. Expansion ratio increased steadily with decrease in feed moisture similar to cereal extrusion. Regions of maxima were observed for sensory preference and shear strength, and these two product attributes were linearly related. The most acceptable chickpea snack was rated higher than a commercial corn snack.

Optimization of extrusion process for production of nutritious pellets

A blend of 50% Potato Starch (PS), 35% Quality Protein Maize (QPM), and 15% Soybean Meal (SM) were used in the preparation of expanded pellets utilizing a laboratory extruder with a 1.5 × 20.0 × 100.0 mm die-nozzle. The independent variables analyzed were Barrel Temperature (BT) (75-140 °C) and Feed Moisture (FM) (16-30%). The effect of extrusion variables was investigated in terms of Expansion Index (EI), apparent density (ApD), Penetration Force (PF) and Specific Mechanical Energy (SME), viscosity profiles, DSC, crystallinity by X-ray diffraction, and Scanning Electronic Microscopy (SEM). The PF decreased from 30 to 4 kgf with the increase of both independent variables (BT and FM). SME was affected only by FM, and decreased with the increase in this variable. The optimal region showed that the maximum EI was found for BT in the range of 123-140 °C and 27-31% for FM, respectively. The extruded pellets obtained from the optimal processing region were probably not completely degraded, as shown in the structural characterization. Acceptable expanded pellets could be produced using a blend of PS, QPM, and SM by extrusion cooking.

Storage effect on the acceptability of snacks made of pure amaranth and blends of amaranth and corn or chickpea

Snacks made by extrusion cooking of pure amaranth flour or mixtures of 80 per cent amaranth flour and 20 per centcorn grits or chickpea flour were developed to replace the traditional commercial ones with improved nutritional and functional quality. Pure amaranth snacks and the blended ones were flavored with salty and sweet flavors and evaluated for acceptability using a 9-point hedonic scale. The good acceptance observed for either salty or sweet flavored snacks indicated that they have characteristics to compete with similar commercial products. Acceptability of salty snacks increased with storage time at room temperature in BOPP (polypropylene bi-guided) packs whereas slightly decreased for the sweet ones. This type of storage proved to be very efficient for the conservation of the salty product and also suitable for the sweet ones

Structural and physicochemical characterization of RS prepared using hydrolysis and heat treatments of chickpea starch

The aim of this study was to evaluate the production and the structural and physicochemical properties of RS obtained by molecular mass reduction (enzyme or acid) and hydrothermal treatment of chickpea starch. Native and gelatinized starch were submitted to acid (2 M HCl for 2.5 h) or enzymatic hydrolysis (pullulanase, 40 U/g per 10 h), autoclaved (121 degrees C/30 min), stored under refrigeration (4 degrees C/24 h), and lyophilized. The hydrolysis of starch increased the RS content from 16% to values between 20 and 32%, and the enzymatic treatment of the gelatinized starch was the most efficient. RS showed an increase in water absorption and water solubility indexes due to hydrolytic and thermal process. The processes for obtaining RS changed the crystallinity pattern from C to B. Hydrolysis treatments caused an increase in relative crystallinity due to the greater retrogradation caused by the reduction in MW. RS obtained from hydrolysis showed a reduction in viscosity, indicating the rupture of molecules. The viscosity seemed to be inversely proportional to the RS content in the sample.

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.

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.

Development of ready-to-eat extruded fish based noodles in semi-rigid containers”

Fish and fishery products are having a unique place in global food market due to its unique taste and flavour; moreover, the presence of easily digestible proteins, lipids, vitamins and minerals make it a highly demanded food commodity.Fishery products constitute a major portion of international trade, which is a valuable source of foreign exchange to many developing countries.Several new technologies are emerging to produce various value added products from food; “extrusion technology” is one among them. Food extruder is a better choice for producing a wide variety of high value products at low volume because of its versatility. Extruded products are shelf-stable at ambient temperature. Extrusion cooking is used in the manufacture of food products such as ready-to-eat breakfast cereals, expanded snacks, pasta, fat-bread, soup and drink bases. The raw materialin the form of powder at ambient temperature is fed into extruder at a known feeding rate. The material first gets compacted and then softens and gelatinizes and/or melts to form a plasticized material, which flows downstream into extruder channel and the final quality of the end products depends on the characteristics of starch in the cereals and protein ingredient as affected by extrusion process. The advantages of extrusion process are the process is thermodynamically most efficient, high temperature short time enables destruction of bacteria and anti-nutritional factors, one step cooking process thereby minimizing wastage and destruction of fat hydrolyzing enzymes during extrusion process and enzymes associated with rancidity.

Comparison of properties of native and extruded amaranth (Amaranthus cruentus L. - BRS Alegria) flour

The aim of this study was to compare some of the properties of native and extruded amaranth flour obtained under mild and severe extrusion conditions. The chemical composition of the flours was similar. Flours obtained by both extrusion processes presented high solubility in water, low values of L* (luminosity) and an absence of endothermic peak on the DSC method. Water absorption, retrogradation tendency, final viscosity and the viscous behavior by rheology analysis were also studied. The results indicate that extruded flours have a good potential as an ingredient for food exposed to heat treatment at a high temperature and mechanical shear, for use in instant meal products. On the other hand, original flour properties are comparable to those of amaranth starch, which exhibits similarly high quality paste stability, low solubility in water, and elastic behavior, and could be used as a substitute for raw flour in a range of food formulas. (C) 2011 Elsevier Ltd. All rights reserved.

Effects of processing methods on amaranth starch digestibility and predicted glycemic index

Amaranth has attracted a great deal of interest in recent decades due to its valuable nutritional, functional, and agricultural characteristics. Amaranth seeds can be cooked, popped, roasted, flaked, or extruded for consumption. This study compared the in vitro starch digestibility of processed amaranth seeds to that of white bread. Raw seeds yielded rapidly digestible starch content (RDS) of 30.7% db and predicted glycemic index (pGI) of 87.2, the lowest among the studied products. Cooked, extruded, and popped amaranth seeds had starch digestibility similar to that of white bread (92.4, 91.2, and 101.3, respectively), while flaked and roasted seeds generated a slightly increased glycemic response (106.0 and 105.8, respectively). Cooking and extrusion did not alter the RDS contents of the seeds. No significant differences were observed among popped, flaked, and roasted RDS contents (38.0%,46.3%, and 42.9%, respectively), which were all lower than RDS content of bread (51.1%). Amaranth seed is a high glycemic food most likely because of its small starch granule size, low resistant starch content (< 1%), and tendency to completely lose its crystalline and granular starch structure during those heat treatments.

Cassava and turmeric flour blends as new raw materials to extruded snacks

Short cooking time and ability to blend varieties of food ingredients have made extrusion cooking a medium for low-cost and nutritionally improved food products. The effect of moisture, extrusion temperature and amount of turmeric flour mixed with cassava flour on physical characteristic of puffed snacks was evaluated in this work. Extrusion process was carried out using a single-screw extruder in a factorial central composite design with four factors. Results showed effect of extrusion parameters on dependents variables. High expansion, low browning, low water solubility index, intermediate water absorption index and high crispness desirable characteristics to puffed snacks are obtained in conditions of 12% moisture, 5% turmeric flour, 105º C of temperature and 250 rpm of screw speed. These paper point to the potential still unexplored of the use of flours of cassava and turmeric as raw materials in the development of extruded puffed snacks.

Development of corn and flaxseed snacks with high-fibre content using response surface methodology (RSM)

With the increasing emphasis on health and well-being, nutrition aspects need to be incorporated as a dimension of product development. Thus, the production of a high-fibre content snack food from a mixture of corn and flaxseed flours was optimized by response surface methodology. The independent variables considered in this study were: feed moisture, process temperature and flaxseed flour addition, as they were found to significantly impact the resultant product. These variables were studied according to a rotatable composite design matrix (-1.68, -1, 0, 1, 1.68). Response variable was the expansion ratio since it has been highly correlated with acceptability. The optimum corn-flaxseed snack obtained presented a sevenfold increase in dietary fibre, almost 100% increase in protein content compared to the pure corn snack, and yielded an acceptability score of 6.93. This acceptability score was similar to those observed for corn snack brands in the market, indicating the potential commercial use of this new product, which can help to increase the daily consumption of dietary fibre.

Efeito das farinhas de jatobá-do-cerrado (Hymenaea stigonocarpa Mart.) in natura e extrusada no metabolismo lipídico e parâmetros fermentativos em hamsters e resposta glicêmica em humanos após a extrusão

Introdução: A polpa farinácea do jatobá-do-cerrado (Hymenaea stigonocarpa Mart.) apresenta alto teor de fibra alimentar, em média 60 g/100 g, que são importantes para a redução do risco e controle de doenças crônicas não transmissíveis (DCNT). A extrusão termoplástica neutraliza aromas intensos, proporciona a formação de amido resistente, aumenta a fibra alimentar solúvel e melhora a textura do produto final. Objetivo: Estudar o efeito das farinhas de jatobá-do-cerrado in natura (FIN) e extrusada (FE) no metabolismo lipídico e parâmetros fermentativos em hamsters, bem como verificar a resposta glicêmica em humanos após a extrusão. Métodos: Processo de extrusão: velocidade de 200 rpm; matriz com 4 mm de diâmetro; taxa de compressão 3:1; alimentação constante de 70 gramas/minuto; temperatura de 150 °C; proporção farinha de jatobá-do-cerrado e amido de milho: 70:30 por cento e umidade a 25 por cento . Foi realizado um experimento animal com hamsters durante 21 dias, em que se analisou alguns parâmetros do metabolismo lipídico e colônico (fermentativos) dos animais, divididos em quatro grupos experimentais, se diferenciando pela dieta. As dietas controle (GC), in natura (GFI) e extrusada (GFE) eram hipercolesterolemizantes (13,5 por cento de gordura de coco e 0,1 por cento de colesterol) e a dieta referência (GR) com óleo de soja como fonte lipídica, não. Todas as dietas apresentavam 15 por cento de fibra alimentar, sendo que as dietas GR e GC tinham como fonte de fibra a celulose, e as dietas GFI e GFE tiveram as próprias fibras como fonte. A resposta glicêmica em humanos foi verificada por meio do ensaio do índice glicêmico e carga glicêmica da FE, com dez voluntários saudáveis que consumiram 25 gramas de carboidratos disponíveis do alimento teste (farinha extrusada) ou do pão branco como alimento controle. Resultados: Não foi observada diferença significativa entre o peso final, ingestão diária média e total, ganho de peso e CEA entre os animais dos quatro grupos. A concentração de triglicerídeos foi menor em 41 por cento e 38 por cento nos animais que receberam as dietas GFI e GFE, em relação aqueles que receberam a dieta GC, assim como também para o colesterol total (55 por cento e 47 por cento ), LDL-c (70 por cento e 53 por cento ) e não-HDL-c (63 por cento e 49 por cento ) séricos, lipídeos totais hepáticos (39 por cento e 45 por cento ) e o peso dos fígados dos animais também foi menor (21 por cento em ambos os grupos). Não houve diferença no colesterol hepático e excretado nas fezes dos animais dos quatro grupos. Os animais do GFE excretaram 57 por cento mais ácidos biliares nas fezes que os animais do GC. Com relação aos parâmetros fermentativos, observou-se maior excreção de fibras (1,24 ± 0,08 e 1,52 ± 0,09 gramas) nos animais dos grupos GR e GC respectivamente, em relação aos do GFI e GFE (0,50 e 0,48 gramas), porém o escore fecal (3,50 ± 0,19 e 3,38 ± 0,18) e o grau de fermentação (54 e 52 por cento ) foi maior nos animais dos grupos GFI e GFE. Houve uma maior produção de AGCC no ceco dos animais dos grupos GFI e GFE (80 e 57,5 µmol/g de ceco respectivamente) e maior diminuição do pH no conteúdo cecal nos animais do grupo GFI (7,49 ± 0,10), em relação ao GC (8,06 ± 0,13). Os ácidos acético e propiônico, estiveram presentes em maior quantidade no ceco dos animais dos grupos GFI (58,5 e 6,1 µmol/g de ceco) e GFE (42,5 e 6,6 µmol/g de ceco) e os animais do GFI produziram mais ácido butírico (15 µmol/g de ceco), em relação aos demais grupos. Quanto à resposta glicêmica da farinha pós extrusão, não houve diferença entre a área de resposta glicêmica da farinha extrusada e do pão branco, o índice glicêmico da farinha extrusada (glicose como controle) foi classificado como moderado, e a carga glicêmica (na porção de 30 gramas), baixa. Conclusão: As FIN e FE favoreceram a redução do colesterol total, LDL-c, não-HDL-c e dos triglicerídeos séricos, além da diminuição do acúmulo de lipídeos hepáticos. Foi observado também aumento expressivo na formação de AGCC e no grau de fermentação. A FE proporcionou um aumento na excreção de ácidos biliares nas fezes e apresentou índice glicêmico moderado e baixa carga glicêmica.

Influence of thermoplastic extrusion on the nutritive value of bovine rumen protein

This Study investigated the impact of thermoplastic extrusion on the nutritive quality of bovine rumen protein. Proximal composition, amino acid profile and in vivo true protein digestibility among rats were determined in raw (RBR) and extruded (EBR) rumen. Raw and extruded bovine rumen presented high percentages of protein (more than 95% on dry basis). Neither raw nor extruded proteins had any limiting amino acid, and the RBR and EBR amino acid scores were, respectively, 1.28 (leucine) and 1.25 (methionine plus cystine). Extrusion reduced significantly true protein digestibility from 97.7% to 93.1% (p < 0.001), but protein digestibility-corrected amino acid scores for both proteins (RBR and EBR) were 100%. Animal growth presented comparable profiles using raw and extruded rumen. In conclusion, thermoplastic extrusion did not affect the protein quality of bovine rumen, and this does not hinder the use of this material as a food ingredient. (C) 2009 Elsevier Ltd. Ail rights reserved.