Effects of extrusion conditions on system parameters and physical properties of a chickpea flour-based snack

Response surface methodology (RSM) was used to study the effects of feed moisture content (16–18%), screw speed (250–320 rpm), and barrel temperature (150–170 °C) on extruder system parameters (product temperature, die pressure, motor torque, specific mechanical energy, SME) and physical properties (expansion, bulk density, hardness) of a chickpea flour-based snack. Second-order polynomials were used to model the extruder responses and product properties as a function of process variables. Product temperature and die pressure were affected by all three process variables, while motor torque and SME were only influenced by screw speed and barrel temperature. All three variables affected product responses significantly. Desirable products, characterized by high expansion ratio and low bulk density and hardness, were obtained at low feed moisture, high screw speed and medium to high barrel temperature. It was demonstrated that chickpeas can be used to produce nutritious snacks with desirable expansion and texture properties.     

Optimum Extrusion-Cooking Conditions for Maximum Expansion of Corn Starch

Normal corn starch was extrusion-cooked in a C. W. Brabender Laboratory model single-screw extruder at various extruder barrel temperatures, screw speeds, feed rates, and moisture contents. The expansion ratios and shear strengths of the products were highly dependent on extrusion-cooking conditions. The maximum expansion ratio of 16.1 was obtained when 14% moisture content (d.b.) starch was fed at a rate of 60g min^-1 with a screw speed of 150 rpm, a barrel temperature of 140°C and a die-nozzle L/D ratio of 3.1. The shear strengths of the extruded starch products were inversely proportional to the expansion ratios.     

Effects of operating conditions on oil loss and structure of almond snacks

An almond‐and‐wheat blend (about 1:2.5, dry basis) was extruded through a co‐rotating twin‐screw extruder with a barrel diameter of 25 mm. The effects of barrel temperature (69.77–120.23 °C), dough moisture (26.64–33.36%) and screw speed (13.85–38.50 rad s^?1) on specific mechanical energy, oil loss that occurs during extrusion process, pressure at the die and on complexing index, break strength, porosity and expansion ratio of extrudates were investigated using response surface methodology. The only variable that had a significant influence on oil loss was barrel temperature (the lowest oil loss, i.e. 0.06%, was obtained with the minimum barrel temperature). The worst product structure was obtained at barrel temperature less than 100 °C. Yet, the highest values of porosity (18.47%) and expansion ratio (158.76%) were obtained at a barrel temperature of 120 °C. Regression results showed a positive correlation (r² = 0.94) between oil loss, porosity and expansion degree values.     

EXTRUSION COOKING OF RICE: EFFECT OF AMYLOSE CONTENT AND BARREL TEMPERATURE ON PRODUCT PROFILE

The effect of amylose content (5.0–28.6%) of rice and barrel temperature (80–120C) on extrusion system parameters torque and net specific mechanical energy and extrudate characteristics extrudate bulk density (ED), water solubility index, expansion ratio (ER) and Warner–Bratzler shear stress were studied using a twin‐screw extruder. The feed rate (15 kgh^?1), moisture content (20.0% ± 0.2) of feed and the screw speed (400 rpm) were kept constant. ED and ER of the product suggested that a barrel temperature of 120C was desirable to generate an expanded extrudate rice product from low‐amylose rice cultivar. Experimental data on system parameters and extrudate characteristics fit to second‐degree polynomial regression equations (r ≥ 0.904, P ≤ 0.01) with the amylose content of rice and barrel temperature of the extruder.     

Effects of Extrusion Process Variables on Quality Properties of Wheat-Ginseng Extrudates

The present study investigated the effects of extrusion process variables (feed moisture, screw speed, and barrel temperature) on the physical [expansion ratio, water absorption index (WAI), and water solubility index (WSI)], pasting, and thermal properties of wheat-ginseng extrudates (WGE). A wheat flour-ginseng powder (GP) blend (10% GP, w/w) was extruded in a twin-screw extruder (L/D ratio of 25:1) with full factorial combinations of feed moisture (25, 30, and 35%), screw speed (200 and 300 rpm), and zone 5 barrel temperature (110, 120, 130, and 140°C). The expansion ratios of WGE were significantly increased with decreasing feed moisture, decreasing screw speed, and increasing barrel temperature. Increasing feed moisture significantly increased WAI values of WGE and significantly decreased WSI values of WGE. However, an increase in either screw speed or barrel temperature caused a significant decrease in WAI values of WGE and a significant increase in WSI values of WGE. Rapid visco analyzer peak viscosity values of WGE were significantly affected by changes in extrusion process variables studied, indicating that the degree of starch degradation and/or gelatinization in WGE is a very important factor associated with their peak viscosity. WAI values of WGE were positively correlated (r = 0.88, p ≤ 0.001) with peak viscosity values of WGE samples, whereas WSI values of WGE samples were negatively correlated (r = 0.82, p ≤ 0.001). Increasing feed moisture resulted in an increase in values of transition peak temperature (T_p) of WGE, whereas increasing screw speed and barrel temperature each led to a decrease in T_p values of WGE, determined by differential scanning calorimetry.     

PROCESS VARIABLES DURING SINGLE-SCREW EXTRUSION OF FISH AND RICE-FLOUR BLENDS

Extrusion cooking of fish and rice‐flour blends in a single‐screw cooking extruder was studied under a wide range of variables of barrel temperature, screw speed, fish content and feed‐moisture content which ranged from 100 to 200C, 70–110 rev/min, 5–45% and 20–60%, respectively. Experiments based on rotatable design showed that the physical properties of expansion ratio, bulk density, hardness and water solubility index (WSI) were significantly affected by all the process variables except screw speed. Barrel temperatures greater than 180C and feed moistures less than 58% result in a steep increase in expansion ratio and a decrease in bulk density. At a fish content of 5% and feed‐moisture content of less than 52.5%, the hardness values decreased. When the WSI is at 40–42% of fish content and the feed‐moisture content is less than 55%, a steep increase was noticed, but a maximum WSI value of 11.5% was observed at a fish content of 41.37% and a feed‐moisture content of 35%.     

Twin-screw Extrusion of Corn Flour and Soy Protein Isolate (SPI) Blends: A Response Surface Analysis

The effects of feed moisture, screw speed, and barrel temperature on physical properties of extruded corn flour and soy protein isolate (SPI) blends were investigated in a co-rotating twin-screw extruder using a response surface methodology. Corn flour and SPI were mixed with a ratio of 4:1. The screw speed was set at five levels between 60 and 140 rpm, barrel temperature between 140 °C and 180 °C, and feed moisture between 18% and 38%. All physical properties of the extruded material evaluated—included expansion ratio, bulk density, breaking strength, water solubility index, rehydration ratio, and color—were significantly (p < 0.05) affected by the three process variables. Feed moisture was the most significant variable with quadratic effects on most of the physical properties. Response surface regression models were established to correlate the physical properties of the extruded product to the process variables. Understanding the effect of these variables on the product physical properties was deemed useful for the development of protein-rich extruded products.     

Effect of extrusion conditions on the physicochemical properties of a snack made from purple rice (Hom Nil) and soybean flour blend

Soy flour was added at levels of 5%, 10%, and 15% of Hom Nil rice flour for extrusion at 190 °C barrel temperature and 350 rpm screw speed. The extruded snack qualities decreased inversely with soy flour. However, product qualities were considered to be optimised when soy flour at 5% was added. The effect of feed moisture content (15, 17, 19 g (100 g)^?1 wb), barrel temperature (150, 170, 190 °C) and screw speed (350, 400, 450 rpm) on physicochemical properties of the snack were then investigated. The physicochemical properties of the product including expansion ratio, density, water absorption index (WAI), water solubility index (WSI) and hardness were evaluated. All properties were related, as linear equations, in terms of feed moisture content, barrel temperature, screw speed with relative correlation (R²) at 0.83–0.94. The snack properties along with consumer acceptance were all highest when the extruded condition were 15 g (100 g)^?1 wb feed moisture content, 170 °C of barrel temperature and 450 rpm of screw speed.     

新型干法工艺制备阳离子淀粉的研究

采用经过改装的挤压反应器作为干法反应装置,以玉米淀粉为原料,以3-氯-2-羟丙基氯化铵(CTA)为醚化剂制备阳离子淀粉。通过单因素试验研究了醚化剂添加量、NaOH添加量、含水量、挤压反应器温度、转速等因素对取代度和反应效率的影响;通过正交试验确定出新型干法制备阳离子淀粉的最佳工艺参数为:醚化剂添加量为5%,NaOH与醚化剂物质的量比为2∶1,水分含量为20%,挤压反应器温度为130℃,转速为400 r/min。研究结果表明,采用改进后挤压反应器制备阳离子淀粉是一种高效、连续、节能的新型干法工艺。     

Effects of Processing Conditions on Single Screw Extrusion of Feed Ingredients Containing DDGS

Distillers dried grains with solubles (DDGS), a feed coproduct from the fuel ethanol industry, has been shown to be a viable potential alternative protein source for aquaculture feeds. To investigate this, three isocaloric (3.5kcal/g) ingredient blends containing 20, 30, and 40% DDGS, with a net protein adjusted to 28% (wet basis, wb), were prepared for use as Nile tilapia feed. Extrusion processing was then conducted using three DDGS contents (20, 30, and 40%, wb), three moisture contents (15, 20, and 25%, wb), three barrel temperature gradients (90–100–100°C, 90–130–130°C, and 90–160–160°C), and five screw speeds (80, 100, 120, 140, and 160rpm) using a single screw laboratory extruder. Several processing parameters, including mass flow rate, net torque required, specific mechanical energy consumption, apparent viscosity, and temperature and pressure of the dough inside the barrel and die, were measured to quantify the extrusion behavior of the DDGS-based blends. For all blends, as the temperature profile increased, mass flow rate exhibited a slight decrease, die pressure decreased, and apparent viscosity exhibited a slight decrease as well. Likewise, the net torque requirement, specific mechanical energy consumption, and apparent viscosity decreased as screw speed increased, but mass flow rate increased. Additionally, as moisture content increased, die pressure decreased. At higher temperatures in the barrel and die, the viscosity of the dough was lower, leading to lower torque and specific mechanical energy requirements. Increasing the DDGS content, on the other hand, resulted in a higher mass flow rate and decreased pressure inside the die. As demonstrated in this study, the selection of suitable temperature and moisture content levels are critical for processing DDGS-based ingredient blends.     

Effect of Thermo-extrusion Process Parameters on Selected Quality Attributes of Meat Analogue from Mucuna Bean Seed Flour

Flour from mucuna beans (Mucuna pruriens) were used in producing texturized meat analogue using a single screw extruder with the intention to monitor modifications on some functional properties of the extrudate. Response surface methodology based on Box Behnken design at three levels of barrel temperature (110, 120, 130°C), screw speed (100, 120, 140 rpm) and feed moisture content (44, 47, 50%) were used in 17 runs. Regression models describing the effect of process variables on the product quality attributes were obtained. Result obtained showed that the moisture contents of the meat analogue samples decreased from 13.23 to 6.53%. Increasing feed moisture content resulted in extruded meat analogue with a higher density (0.988), water absorption index (WAI) (2.30), oil absorption index (OAI) (2.350), swelling power (3.47) and lower lateral expansion (0.84). Lateral expansion, OAI and swelling power increased as barrel temperature increased with peak values of 1.39, 2.39 and 3.47 respectively, while bulk density and WAI decreased. The product functional responses with coefficients of determination (R²) ranging between 0.658 and 0.894 were most affected by changes in barrel temperature and feed moisture and to lesser extent by screw speed. Optimization results based on desirability concept indicated that a barrel temperature of 120.15°C, feed moisture of 47% and screw speed of 119.19 rpm would produce meat analogue of preferable functional properties.     

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.     

Effect of Starch Sources on Properties of Extrudates Containing DDGS

Various levels of DDGS (20, 40, and 60% wb) were blended with starch sources (cassava, corn, and potato), and other ingredients to produce an iso-nitrogenous feed (28% protein) at varied moisture contents (15, 20, and 25% wb). The feed blends were extruded in a single-screw extruder at a preset screw speed of 130 rpm (13.6 rad/s) with three temperatures profiles 90–100–100°C, 90–120–120°C, and 90–140–140°C. The effect of these variables on processing conditions (extruder torque and die pressure) and other extrudate properties (expansion ratio (ER), unit density (UD), color (L*, a*, and b*), sinking velocity (SV), water absorption, water solubility, and pellet durability indices (PDI)) were analyzed. For all the three starch extrudates, changing the levels of DDGS, feed moisture content, and extruder barrel temperature had a significant effect on SV, PDI, a*, and b* values at α = 0.05.     

Physico‐chemical and antioxidant properties of extrudates developed from honey and barley

Barley flour and honey, being concentrated source of nutrients, were used to develop extruded product using twin‐screw extruder. Response surface methodology was applied to study the effects of honey (5–25%), moisture content (17–21%) temperature (120–160 °C) and screw speed (180–220 rpm) on product responses. The variation in moisture content and die temperature affected the physicochemical properties of extrudate but screw speed had significant effect only on hardness. It was established that with increase in honey levels from 5% to 20%, there was increase in antioxidant activity (up to 106.9%), total phenolic content (up to 90.2%) and total flavonoid content (up to 89.2%) in interaction with other extrusion cooking variables. The optimal condition corresponds to honey content of 18.86%, feed moisture of 18%, die temperature of 148.62 °C and screw speed of 209.99 rpm. The results suggest that honey can be extruded with barley flour into a healthful snack food.     

The Effects of Extrusion Conditions on the Physical Properties of Wheat Flour Extrudates

The effects of extrusion conditions (feed moisture content and rate, process temperature, screw speed and geometry, and die diameter) on expansion ratio, bulk density, and breaking strength of wheat flour extrudates were investigated. Extrudate samples were prepared by using a Brabender single-screw extruder. Higher feed moisture content and process temperature were required for proper expansion. At 3.18mm die opening, the relationship between expansion and bulk density was positive. Feed rate was the most effective factor for increasing bulk density. Breaking strength was significantly decreased with increasing process temperature. Under extrusion conditions of 22% feed moisture, 110g/min feed rate, 160°C process temperature, and 130rpm screw speed with 5:1 CR, wheat flour was puffed with low bulk density and breaking strength.     

Response surface analysis and extrusion process optimisation of maize–mungbean‐based instant weaning food

This study was conducted to produce high‐quality weaning food from easily available and low‐cost raw materials by extrusion technology. Weaning mix was developed using extrudates of maize (Zea mays) and mungbean (Vigna radiata) flour with a twin‐screw extruder. Experiments were designed using three independent variables [feed moisture (12.6 – 19.4%), screw speed (349 – 601 rpm) and barrel temperature (108 – 192 °C)] and five dependent variables (specific mechanical energy, bulk density, water absorption index, water solubility index and degree of gelatinisation) at five levels of central composite rotatable design (CCRD). Optimisation results indicated that feed moisture of 14.33%, screw speed of 524 rpm and barrel temperature of 174 °C would produce maize–mungbean extrudates of preferable functional properties. The optimised weaning mix contained maize–mungbean extrudates 40%, skim milk powder 35% and sugar 25% (w/w). The nutrient content of the weaning mix was in accordance with the standards specified by PFA, (2004) with high protein and starch digestibility.     

Effect of operating conditions on physical characteristics of extruded rice starch

The effect of screw speed, flow rate, barrel temperature and added moisture on physical characteristics of high moisture extruded rice starch was studied. the product physical characterization was made by measuring density, final moisture content and the maximum load force in a puncture test. Rice flour containing approximately 1.5% protein and 6% moisture was mixed with 55–65% (w/w) water and extruded in a co-rotating twin screw extruder with a slit die. A two level factorial design was used to analyse each parameter. It was found that added moisture was the most important variable affecting the force-deformation curve maxima, with the interaction between added moisture and barrel temperature exhibiting a less significant effect. Added moisture and flow rate each affected density, with the interaction between added moisture and screw speed showing a less significant effect. Temperature and flow rate affected final moisture interactively with added moisture, which was evidently the most important variable.     

全脂米糠膳食纤维化挤压及可溶性工艺技术研究

为了探索全脂米糠粉挤压规律,以纤维素酶为催化剂,利用双螺杆挤压机做生化反应器对全脂米糠粉进行了挤压试验研究,获得了具有不同膳食纤维含量的挤出物。在单因素研究的基础上,采用了五元二次正交旋转组合设计(1/2)实施研究了机筒温度、螺杆转速、物料水分、加酶量和模孔直径对挤出物膳食纤维含量的影响规律。结果表明:5个因素对膳食纤维得率的影响大小依次为水分(X2)机筒温度(X4)pH值(X1)酶添加量(X3)螺杆转速(X5)。在pH值6.5、水分39%、加酶量3.5%、转速110r/min和机筒温度125℃条件下,所得全脂米糠粉中膳食纤维产率为33.51%。可溶性膳食纤维含量为9.9%。     

大豆蛋白高水分挤压组织化过程中工艺参数对系统压力和扭矩的影响

以食用脱脂低温豆粕为原料,用响应面分析法,研究了DSE-25型双螺杆挤压机在大豆蛋白高水分挤压组织化过程中工艺参数对系统压力和扭矩的影响。结果表明,机筒温度、物料水分含量、喂料速度和螺杆转速等操作参数对挤压机系统压力和扭矩均具有显著的影响。系统压力随着机筒温度和物料水分含量的升高而降低,随着喂料速度的增加而增加,螺杆转速对其影响较小;扭矩随物料水分含量的增加而降低,随着机筒温度和螺杆转速的升高均表现出先升后降的趋势,随喂料速度的增加则表现出先降后升的趋势。依据逐步回归分析法建立的双螺杆挤压机系统参数的统计模型,具有较高的预测精度,可用于挤压过程的控制和挤压结果的预测。     

EFFECT of EXTRUSION VARIABLES ON EXTRUDATE CHARACTERISTICS of FISH MUSCLE-RICE FLOUR BLEND IN A SINGLE-SCREW EXTRUDER

Effects of extrusion variables on extrudate characteristics of fish muscle-rice flour blend containing intermediate moisture (30–50%) were studied in an indigenously developed single screw cooking extruder. Data analysis of the statistically designed response surface experiments showed that expansion ratio and bulk density of extrudates were most influenced by the barrel temperature followed by fish content of the feed. In contrast fish and moisture contents of the feed significantly influenced hardness. A set of optimum process conditions was arrived at 160C barrel temperature, 12% fish content and 27% moisture content. Under these conditions experimental expansion ratio and bulk density matched well with the values predicted from the response model, but hardness deviated significantly. Experimental properties of the extrudates were not, however, affected by the fish variety.