Modeling Shearing Resistance of Powdery Starch for Simulation Studies of Extrusion Cooking Processes

Modeling extrusion cooking of starch requires the use of appropriate intrinsic kinetic equations. Knowledge of shear stress profile in a particulate system such as that in the transition zone of an extruder is crucial for calculation of degrees of conversion (gelatinization and melting) of starch. Shearing resistance of moistened powder starch as affected by temperature, normal pressure, effective shear rate, moisture content, and degree of starch conversion was studied in a model system. A modified vane shear testing device was used for experimental measurement of each individual effect. Within the experimental ranges studied (temperature 30 to 80°C, moisture content 16 to 35%, effective shear rate 0 to 550 s⁻¹, starch conversion 0 to 0.36 (36%), and normal pressure 0 to 83 kPa) parameter values in each functionality were evaluated. A single mathematical model useful for calculating shear stress was obtained by combining these effects in a single relationship. A good correlation was shown when the calculated shear stress was plotted against the experimentally measured. The methodologies developed here are useful for the studies of powdery food materials. The potential application of this correlation to the simulation of extrusion processes was discussed.     

BACK EXTRUSION and SIMULATION of VISCOSITY DEVELOPMENT DURING STARCH GELATINIZATION

A generalized apriori theoretical model relating apparent viscosity of protein dough to several independent variables was used to model gelatinized starch dispersions. Independent variables in the original model were shear rate, temperature, moisture content, temperature-time history and strain history. the model is applied here to corn starch dispersions gelatinized using various temperature-time treatments. Apparent viscosity of a 13.7% gelatinized cornstarch solution at constant shear rate and strain history was measured at 20 C using a back extrusion technique. Activation energy of gelatinization was estimated as 210 kJ/mol (50 kcal/mol) over the range 81–95 C. the activation energy decreased in the range 95–105 C.     

Rheological Modeling of Corn Starch Doughs At Low to Intermediate Moisture

A generalized model for predicting the extrudate viscosity of starch based products at low to intermediate moisture content is presented. It incorporates the effects of shear rate, temperature, moisture content, time-temperature history and strain history. The model was tested using corn starch dough at various moisture contents. An Instron capillary rheometer and a Baker Perkins MPF 50 D/25 co-rotating twin screw extruder were used to collect all data. Viscosity was found to be a function of cook temperature and moisture content but not cook time. Observed versus predicted viscosity gave an R² of 0.975 after accounting for shear rate, temperature, moisture content and time-temperature history in the capillary rheometer. Extrusion tests indicated that correction for strain history was important for highly puffed extrudates.     

挤压温度和物料水分对糙米粉中损伤淀粉及面条品质影响

在不同挤压温度和物料水分条件下将糙米粉挤压膨化,并将挤压膨化糙米粉与小麦粉的混合粉(1∶1,w/w)制成糙米面条,系统研究了挤压温度和物料水分对挤压糙米粉中损伤淀粉含量和糙米面条品质的影响,同时分析了损伤淀粉含量与面条品质的相关性。结果显示:随着物料水分的增加,糙米粉中损伤淀粉的含量显著减少,物料水分25%时损伤淀粉含量UCDc值达到最低14.9;随着挤压温度升高,糙米粉损伤淀粉含量先减少后增加,温度120℃时损伤淀粉含量UCDc值达到最低14.9;相关性分析结果显示,随着损伤淀粉含量的增加,面条蒸煮损失明显增大,坚实度、硬度和耐咀性降低,面条整体品质下降。挤压温度120℃、物料水分25%、损伤淀粉含量UCDc值为14.9,糙米面条品质相对较好。      

Rheological properties and phase transition of cornstarches with different amylose/amylopectin ratios under shear stress

The rheological properties and phase transition of cornstarch with low moisture content under shear stress was investigated using a mixer with twin‐roller rotors by the variation of torque as functions of temperature and time. Cornstarches with different AM/AP ratios (wx: 4:96, maize: 29:71, Gelose 50: 62:38, and Gelose 80: 77:23) were used as model materials in the experimental work. The results showed that, as the AM content increased from 0 to 77%, the maximum torque increased from about 54 to 66 N/m and the final torque increased from about 27 to 47 N/m, respectively, and a longer mixing time was required to achieve a stable state (constant torque value). Microscopic and differential scanning calorimetry (DSC) studies showed that the phase transition reflected by changes of birefringence and endotherms could well be associated with the torque curve measured by the mixer. The higher gelatinization temperatures of the starches with higher AM content, and especially the existence of multi‐phase transitions at high temperatures, could explain the rheological behaviors detected by the mixer. The technique can be used to study the starch melting and destructuration under shear stress with low moisture content (<45%), which represents the most of extrusion conditions for starch‐based materials.     

挤压处理对豌豆淀粉的流变特性和体外消化率的影响

目的:研究挤压条件(豌豆淀粉水分质量分数:25％、35％、40％、45％和55％;剪切温度:50、60、70、80?℃和90?℃;螺杆转速:100、120、140、160?r/min和180?r/min)对豌豆淀粉的体外消化率和流变特性的影响.方法:采用体外消化法测定了豌豆淀粉的水解度,并通过稳态剪切实验、频率扫描实验...     

Physicochemical Properties of Casein‐Starch Interaction Obtained by Extrusion Process

Extruded samples of starch‐casein blends were processed by using a single‐screw extruder. The independent variables in the process were temperature (126–194°C), moisture content (18–29%) and starch‐casein blend (5–95%). These independent variables affected significantly the physicochemical and textural properties of the biopolymers. The highest values for expansion (EXP) and water absorption index (WAI) were found when a higher starch proportion was present in the blends, at 126°C barrel temperature and moisture content higher than 25%. By increasing the barrel temperature, from 126°C to 194°C, the water solubility index (WSI) and color parameter were increased. Initial viscosity (IV) and viscosity at 90°C (V90) were mainly affected by the barrel temperature at 194°C. However, the viscosity at 50°C (V50) was affected neither by the different extrusion variables nor by the biopolymer proportion in the blends. Compression force (CF) was strongly dependent on moisture content and casein proportion in the blend. The higher CF values were found at starch concentrations around 50% and 25% moisture content, for higher or lower values than these the obtained extruded products were softer and consequently had lower CF values.     

Extrusion of pea starch containing lysozyme and determination of antimicrobial activity

ABSTRACT:  Pea starch, which has inherently good gel strength, was used as the source material for manufacturing a biodegradable and bioactive packaging material. Extrudates containing 99% pea starch and 1% lysozyme were produced under various extrusion conditions (high and low shear screw configurations, 30% to 40% moisture contents, 70 to 150 °C die temperatures). The physical and mechanical properties of the extrudates were determined through various expansion indices, piece and cell wall solid density, compression, and 3-point bending tests. The expansion of extrudates increased with an increase in die temperature, whereas increasing moisture content had the opposite effect. Extrudate densities decreased as extrusion temperature increased, whereas lower moisture content in the extrudate dough decreased extrudate densities. The elastic modulus and fracture strengths were highly correlated in a power-law fashion to relative density, showing that the mechanical properties of extrudates were dependent on solid density and foam structure. Up to 48% of the initial lysozyme activity was recovered from the extruded pea starch matrix. The lysozyme released from extrudates showed an inhibition zone against Brochotrix thermosphacta B2 . Extruded pea starch matrix containing lysozyme has potential application as an edible and biodegradable packaging material with antimicrobial activity.     

Extrusion of Hulled Barley Affecting β-Glucan and Properties of Extrudates

Grits from eight different hulled barley cultivars were subjected to extrusion cooking on a twin screw extruder, and the effect of extrusion variables (temperature and moisture) on β-glucan and physicochemical properties was evaluated. The highest bulk density was observed for extrudates extruded at 150 °C and 20% moisture (low temperature high moisture, LTHM) while the highest expansion was observed for the extrudates extruded at 150 °C and 15% moisture (low temperature low moisture). Extrusion reduced the lightness (L*) of the extrudates and the highest decrease observed for LTHM extrudates. Increasing the feed moisture decreased water solubility index (WSI) significantly while increasing the extrusion temperature significantly increased WSI. The high temperature high moisture (HTHM) extrudates exhibited the highest water absorption capacity. The total β-glucan content was not affected by extrusion cooking, but a significant increase in soluble β-glucan was observed with the highest in high temperature low moisture extrudates. The ratio of soluble to insoluble β-glucan varied from 0.7 to 1.5 in the control barley, but after extrusion cooking, the ratio was changed from 1.2 to 3.1. The β-glucan extractability increased by up to 8% after extrusion with extrudates from HTHM showing the highest extractability. The extent of starch gelatinization varied from 80% to 100% upon extrusion, and the highest was observed in HTHM extrudates. A significant decrease in the peak and final viscosity of the extrudates at all the extrusion conditions was observed.     

Influence of time-temperature history and strain history on the melt rheology of soy protein isolate at an elevated temperature

Reciprocating extrusion and single extrusion experiments were performed using a completely air-tight capillary extrusion viscometer in order to elucidate the effects of time-temperature history and strain history on the melt rheology of soy protein isolate (SPI) at an elevated temperature (140°C). Both histories produced a decrease in the measured pressure drop during extrusion and these effects were strongly dependent on the sample moisture content. For moisture contents above 41% (dry basis), the time-temperature history effect was predominant more in decreasing the measured pressure drop, whereas the strain history effect was more influential at moisture contents below 30% (d.b.)     

RHEOLOGICAL BEHAVIOUR OF COCOA DISPERSIONS

The steady-shear viscosities of cocoa mass and cocoa suspensions were measured over a wide range of temperature and cocoa powder content. The effects of gasification, moisture and lecithin contents were also investigated. The viscosity of cocoa mass followed the Quemada or the Casson model. Both viscosity and yield stress decreased with increasing temperature. Degasification also lowered the viscosity and yield stress. The viscosity of concentrated cocoa suspension increased with increasing powder content and exhibited shear-thinning behaviour, and followed the Kreiger and Dougherty model. While the relative intrinsic viscosity was nearly constant, the maximum volume fraction increased with increasing shear stress or shear rate. Addition of moisture in suspension increased the viscosity due to partial gelation of starch; while addition of lecithin decreased the viscosity due to the lesser number of flocs in the suspension.     

Rheological analysis of dough prepared with lentil flour at different moistures for production of extruded products

Extruded products like expanded puff product are prepared from lentil (Lens culinaris Medik) at different conditioning moisture (14, 18, 22 %) for constant temperatures, range from 100 to 210 °C, which was used during extrusion processing. The present study was aimed to investigate the effect of conditioning moisture at different temperature on the rheological behavior of lentil. It was determined that viscosity and yield stress of the lentil dough decreased with increase in conditioning moisture of flour used during extrusion process. Yield stress decreased by 68 and 80 % for conditioning moisture at 18 and 22 %, respectively as compared to those conditioning moisture at 14 %. This was attributed to the changes in the carbohydrates occur due to high extrusion temperature. Increasing the conditioning moisture during extrusion process decreased the fluid consistency index and increased the flow behavior index of the dough, demonstrating a lower viscosity and increased fluidity. All the samples revealed shear thinning behavior. The dough prepared using lentil shows depletion in gelatinization temperature with decreased in conditioning moisture as demonstrated by viscoelastic analysis (loss modulus, storage modulus, Tan δ) of the samples.     

湿热处理对甘薯淀粉流变特性的影响

目的:采用HAAKE MARSⅢ型流变仪研究不同湿热处理条件下甘薯淀粉的流变性。方法:通过控制湿热处理的水分(10%~30%)、温度(90~130 ℃)和时间(4~12 h)对甘薯淀粉进行湿热改性。结果:原淀粉与湿热改性淀粉的糊具有明显的剪切稀化行为,其流变曲线也服从Herschel-Bulkley模型。不同湿热处理条件下得淀粉糊浓度系数K、屈服应力τ₀均低于原淀粉(K_原=14.816 Pa·sⁿ,τ_0原=10.322 Pa),流动特性指数n高于原淀粉(n_原=0.47)。随着湿热处理水分、温度与时间的增加,淀粉糊的K逐渐减小,τ₀则先增后减,湿热处理水分20%,温度110 ℃,时间8 h的屈服应力最大(τ_0上行线=5.683 Pa,τ_0下行线=12.423 Pa)。动态流变学特性表明:不论湿热改性与否,甘薯淀粉糊的储能模量(G')均大于损耗模(G″)。并且相对于原淀粉,湿热改性甘薯淀粉糊的黏弹性明显增加。结论:经过湿热处理,甘薯淀粉糊的浓度系数与屈服应力下降,非牛顿性减弱,黏弹性显著提高,更适合作为食品加工的辅料和添加剂。     

Effects of extrusion variables on the properties of waxy hulless barley extrudates

The objective of this research was to investigate the extrudability of waxy hulless barley flour under various extrusion conditions. Waxy hulless barley flour was processed in a laboratory-scale corotating twin-screw extruder with different levels of feed moisture content (22.3, 26.8, and 30.7%) and die temperature (130, 150, and 170 degrees C) to develop a snack food with high beta-glucan content. The effects of extrusion condition variables (screw configuration, moisture, and temperature) on the system variables (pressure and specific mechanical energy), the extrudate physical properties (sectional expansion index, bulk density), starch gelatinization, pasting properties (cold peak viscosity, trough viscosity, and final viscosity), and beta-glucan contents were determined. Results were evaluated by using response surface methodology. Increased extrusion temperature and feed moisture content resulted in decreases in exit die pressure and specific mechanical energy values. For extrudates extruded under low shear screw configuration (LS), increased barrel temperature decreased sectional expansion index (SEI) values at both low and high moisture contents. The feed moisture seems to have an inverse relationship with SEI over the range studied. Bulk density was higher at higher moisture contents, for both low and high barrel temperatures, for samples extruded under high shear screw configuration (HS) and LS. Cold peak viscosities (CV) were observed in all samples. The CV increased with the increase in extrusion temperature and feed moisture content. Although beta-glucan contents of the LS extrudates were comparable to that of barley flour sample, HS samples had generally lower beta-glucan contents. The extrusion cooking technique seems to be promising for the production of snack foods with high beta-glucan content, especially using LS conditions.     

Preparation of oxidized corn starch in a screw extruder under alkali‐free conditions

To promote water solubility of oxidized starch prepared by the dry process, a twin screw extruder was used as a reactor in the present study. Through single‐factor experiments and orthogonal experiment, the effects of barrel temperature, moisture content, addition amount of NaOCl, and screw speed on the carboxyl content (CC) and water solubility index (WSI) of oxidized corn starch were investigated. The results indicated that high screw speed, medium barrel temperature, and low moisture content could lead to high WSI of oxidized corn starch produced by extrusion. The reaction efficiency and solubility of oxidized starch prepared by reactive extrusion under the optimal condition were all improved greatly, especially the WSI was very high (99.56%). Preparation of oxidized starch by reactive extrusion under alkali‐free conditions could be described as a rapid (only several minutes), continuous, reduced addition amount of NaOCl, eco‐friendly new dry technology.     

Application of an In‐line Viscometer to Determine the Shear Stress of Plasticised Wheat Starch

An in‐line viscometer was designed and constructed to enable determination of the shear stress of plasticised wheat starch during extrusion cooking. The viscometer was installed between the end of the barrel section and the extruder die plate so that the shear stress could be determined for the plasticised material, irrespective of the geometrical shape into which it was subsequently moulded by the extruder die. The extrusion conditions were described in terms of the process parameters, i. e. water content, barrel temperature, screw speed and screw configuration; and of the system parameters, which were the specific mechanical energy input (SME), product temperature (PT) and mean residence time (MRT). The parameters were measured and the results evaluated using statistical methods. Regression equations were used to describe functional relationships between the shear stress and the extrusion conditions on the one hand, and between the shear stress and the product characteristics of the extrudates on the other. The shear stress of plasticised wheat starch determined in‐line can be used to predict the morphological structure (volumetric expansion) and the functional properties (cold paste viscosity and cold water solubility) of extruded, directly expanded starch with a high degree of accuracy. The measurement technique used and the results of the extrusion tests undertaken for this project will therefore enable the shear stress of plasticised material in an extruder to be used as the principle parameter for controlling extruders on‐line.     

挤压预糊化淀粉的性能及其添加对糙米发糕品质的影响

通过挤压不同水分含量（45%、25%和18%）的大米淀粉制备预糊化大米淀粉,测定其分子量、结晶度、糊化度、水吸收指数、水溶解指数、冷糊黏度等指标,并考察了预糊化淀粉添加对糙米粉糊化特性及糙米发糕品质的影响。结果表明,与原大米淀粉相比,45%、25%和18%水分含量挤压制备的预糊化大米淀粉结晶度分别降低了51.93%、58.93%和59.04%;水吸收指数分别提高了1.56、4.69和6.11倍;水溶解指数分别提高了7.04、16.30和27.64倍;冷糊黏度分别提高了2.00、21.44和14.67倍。挤压还使大米淀粉分子发生降解,产生了更多的小链分子。预糊化大米淀粉性能变化与挤压过程中淀粉的水分含量有关。添加预糊化大米淀粉显著提高了糙米发糕的品质（P<0.05）,高的冷糊黏度和低的分子量（18%水分挤压）更有利于制备比容大（1.64 cm3/g）、孔洞细腻均匀、硬度低（338.59 g）和有弹性的糙米发糕。     

Effects of Extrusion Temperature and Plasticizers on the Physical and Functional Properties of Starch Films

Cornstarch, at 20% moisture content (dry basis, d.b.), was mixed with glycerol at 3:1 ratio to form the base material for extruded starch films. Stearic acid, sucrose and urea, at varying concentrations, were tested as secondary plasticizers for the starch‐glycerol mixture. The ingredients were extruded at 110 and 120°C barrel temperatures to determine the effects of extrusion temperature, plasticizer type and their concentrations on the film‐forming characteristics of starch, as well as their effects on selected physical and functional properties of the films. The physical and mechanical properties of the films were studied by scanning electron microscopy (SEM) and tensile testing, while the glass transition and gelatinization properties were analyzed using differential scanning calorimetry (DSC). The interactions between the functional groups of starch and plasticizers were investigated using Fourier‐transform infrared (FTIR) spectroscopy. The water vapor permeability (WVP) properties of starch films were determined using ASTM standard E96‐95. Scanning electron micrographs exhibited the presence of native and partially melted starch granules in the extruded films. The tensile stress, strain at break and Young's modulus of starch films ranged from 0.9 to 3.2 MPa, 26.9 to 56.2% and 4.5 to 67.7 MPa, respectively. DSC scans displayed two glass transitions in the temperature ranges of 0.1 to 1°C and 9.6 to 12°C. Multiple melting endotherms, including that of amylose‐lipid complexes, were observed in the thermoplastic extrudates. The gelatinization enthalpies of the starch in the extruded films varied from 0 to 1.7 J/g, and were dependent largely on the extrusion temperature and plasticizer content. The shift in the FTIR spectral bands, as well as the appearance of double‐peaks, suggested strong hydrogen bonding interactions between the starch and plasticizers. The WVP of starch films ranged from 10.9 to 15.7 g mm h^‐1 m^‐2 kPa^‐1, depending on the extrusion temperature and the type of plasticizer used.     

Effect of processing conditions on some functional characteristics of extrusion‐cooked cassava starch/wheat gluten blends

Extrusion‐cooked blends of cassava starch (CS) and wheat gluten (WG) were studied. The data were analysed using response surface methodology. The results showed the formation of new structures characterised by lower radial expansion (RE) and specific volume (SV) when gluten was added to CS. WG content was the most important variable affecting RE, water absorption index (WAI), water solubility index (WSI), SV and difference in colour (ΔE) of the extruded products, but feed moisture content and barrel temperature also influenced RE. WAI was affected by a significant interaction between WG content and barrel temperature. The extruded products had lower WAI values and higher WSI values than WG‐free products. Heat, high shear rate and high pressure during extrusion cooking caused mechanical destruction or denaturation of the WG and gelatinisation and dextrinisation of the starch components. The extruded blends could have diverse applications. © 2002 Society of Chemical Industry     

Restructuring of Mechanically Deboned Chicken and Nonmeat Binders in a Twin-screw Extruder

A twin-screw cooking extruder was used to restructure mechanically deboned chicken (MDC) in combination with three nonmeat binders, corn starch (CS), soy protein isolate (SPI) and wheat gluten (WG), at concentrations of 10–30%. Extrudates were evaluated by apparent tensile stress (ATS), Warner Bratzler shear stress (WBSS), proximate composition and reheat yield. SPI and WG were less effective than starch for increasing the ATS and WBSS of extruded MDC. The effects of die temperatures between 71–115°C on chemical and textural properties of extrudates containing 10% and 15% starch were investigated. The ATS and WBSS increased as a function of temperature up to 104°C. Fat content and lipid oxidation decreased as extrusion temperatures increased.