Changes in the Functional Properties and Antinutritional Factors of Extruded Hard-to-Cook Common Beans (Phaseolus vulgaris,L.)

ABSTRACT: The biochemical and functional properties of 2 hard-to-cook common bean cultivars (Phaseolus vulgaris, L.) were investigated after the extrusion process. Beans of BRS pontal and BRS grafite cultivars were milled and extruded at 150 °C, with a compression ratio screw of 3 : 1, 5-mm die, and screw speed of 150 rpm. Extrudate flours were evaluated for water solubility (WS), water absorption index (WAI), oil absorption capacity (OAC), foaming capacity (FC), emulsifying activity (EA), antinutritional factors, and in vitro protein and starch digestibility. Results indicated that the extrusion significantly decreased antinutrients such as phytic acid, lectin, α-amylase, and trypsin inhibitors, reduced the emulsifying capacity and eliminated the FC in both BRS pontal and BRS grafite cultivars. In addition, the WS, WAI, and in vitro protein and starch digestibility were improved by the extrusion process. These results indicate that it is possible to produce new extruded products with good functional and biochemical properties from these common bean cultivars.     

EXTRUSION BEHAVIOUR AND PRODUCT CHARACTERISTICS OF BROWN AND MILLED RICE GRITS

ABSTRACT

Extrusion behaviour of milled and brown rice grits obtained from six rice cultivars (Jaya, IR-8, PR-103, PR-106, Pusa No.1 and Basmati 385) was investigated using Brabender single screw extruder. Feed moisture of the grits was adjusted to 16%, and extrusion cooking was done at barrel temperature of 150°C and screw speed of 100 rpm. The milled and brown rice grits from different rice cultivars differed significantly with respect to extrusion behaviour and extrudate characteristi cs. Extrudates obtained from milled rice grits showed higher die pressure, expansion, water absorption index (WAI) and water solubility index (WSI) as compared to those from brown rice. WSI of extrudates varied from 3.38 to 10.5%, WAI from 5.20 to 6.90, die pressure from 6068 to 9325 kPa and expansion from 7.52 to 11.30 respectively. The grits from cultivars which had lower length-breadth ratio and mealy endosperm resulted into more expanded extrudates and hence were found to be more suitable from extrusion.     

The optimization of the extrusion process when using maize flour with a modified amino acid profile for making tortillas

Maize with a modified amino acid profile, i.e. greater amounts of lysine and tryptophan than normal, is known as ‘quality protein maize’ (QPM). The objective of this work was to find the best combination of extrusion process variables to produce QPM flour for making tortillas. QPM grits were mixed with lime and water and had a moisture content of 28%. The single screw extruder operation conditions were selected from factorial combination of three process variables: extrusion temperature (ET, 70–100 °C), lime concentration (LC, 0.1–0.3% of the maize weight) and screw velocity (SV, 80–250 rpm). Response surface methodology was used as an optimization technique. In vitro protein digestibility (PD); total colour difference (ΔE) of the flours, and tortilla puffing (TP) were chosen as response variables. A graphical method was used to obtain maximum PD, TP and minimum ΔE. The optimum combination of process variables was: ET = 85 °C/LC = 0.21%(w/w)/SV = 240 rpm. Tortillas from QPM flour had similar chemical composition, physicochemical and sensory properties to tortillas from commercial nixtamalized maize flour; however, the former had the highest (P ≤ 0.05) available lysine content and were therefore better nutritionally.     

薯类原料膨化特性及其膨化粉品质特性

本实验以4 种薯类全粉（马铃薯、紫马铃薯、甘薯、紫甘薯）为原料,考察了不同薯类原料样品的膨化特 性,并采用质构仪、快速黏度分析仪及稳定性分析仪对不同薯类膨化粉的品质特性进行研究。结果表明：4 种薯类 原料中,马铃薯类原料膨化特性显著优于甘薯类原料,其中马铃薯样品膨化度、糊化度以及水溶性指数较高,容积 密度较低,膨化性能最好;相关性分析表明,不同薯类原料膨化特性的差异与物料基本组分的变化率有关;马铃薯 类原料坚实度、稠度、低谷黏度、回生值及回生值/峰值黏度显著低于甘薯类原料,说明马铃薯类膨化粉熟化度高、 口感好,其中马铃薯样品显著优于紫马铃薯（P＜0.05）;稳定性分析仪图谱及稳定性动力学指数均显示马铃薯类原 料的分散稳定性显著优于甘薯类原料,其中马铃薯样品显著优于紫马铃薯（P＜0.05）。综上可知,4 种薯类原料中, 马铃薯类原料膨化特性及其膨化粉品质特性整体显著优于甘薯类原料,其中马铃薯样品性能最佳。     

Nixtamalisation of maize (Zea mays L) using a single screw cook-extrusion process on lime-treated grits

The tortilla flour market is expanding but present industrial production is lagging behind in the use of modern technologies to increase production and cut costs due to the maize steeping and drying operations. A process using a single-screw cook-extruder which eliminates the traditional steeping and drying operations was therefore explored. Lime (Ca(OH)₂) suspension was absorbed onto commercial maize grits (2 g lime kg^?1 maize) and the resulting meal conditioned to various moisture contents. These samples and one which had not been lime-treated were cook-extruded through a Brabender Do-corder extrusion cooker (Type 825602). The dry extrudate was milled through a 150 μm sieve and tortillas made from each sample. The tortillas prepared from the lime-treated grits conditioned to 472 g kg^?1 moisture compared favourably with that prepared from traditionally prepared masa flour when organoleptically assessed. Flour pasting properties (viscosity) and water absorption index were not significantly different (P < 0.05) from the traditionally prepared products. Enzyme susceptible starch index did not correlate well with dough quality.     

Stability of zearalenone during extrusion of corn grits

The effects of extrusion cooking on the stability of zearalenone (ZEN) in spiked (4.4 microg/g) food-grade corn grits were investigated using a twin screw extruder. A ground rice culture material containing a high level of ZEN was used to spike the corn grits. The extrusion variables were screw type (mixing and nonmixing), temperature (120, 140, and 160 degrees C), and moisture content (18, 22, and 26%). Both unextruded and extruded samples were analyzed for ZEN by high-performance liquid chromatography. Extrusion cooking of the corn grits resulted in significant reductions of ZEN in grits extruded with either mixing screws or nonmixing screws, but use of mixing screws was somewhat more effective (66 to 83%) overall than nonmixing screws (65 to 77%). Greater reduction of ZEN was observed at either 120 or 140 degrees C than at 160 degrees C. The moisture content of corn grits was not a significant factor affecting reduction of ZEN during extrusion with either mixing or nonmixing screws.     

Reduction of fumonisin B₁ in corn grits by twin-screw extrusion

Abstract: This study was designed to investigate the fate of fumonisins in flaking corn grits during twin‐screw extrusion by measuring fumonisin B₁ (FB₁) and its analogs with a mass balance approach. Food grade corn grits and 2 batches of grits contaminated with FB₁ at 10 and 50 μg/g by Fusarium verticillioides M‐2552 were processed with or without glucose supplementation (10%, w/w) with a twin‐screw extruder. Extrusion reduced FB₁ in contaminated grits by 64% to 72% without glucose and 89% to 94% with added glucose. In addition, extrusion alone resulted in 26% to 73% reduction in the levels of fumonisin B₂ and fumonisin B₃, while levels of both mycotoxins were reduced by >89% in extruded corn grits containing 10% glucose. Mass balance analysis showed that 38% to 46% of the FB₁ species detected in corn extruded with glucose was N‐(deoxy‐D‐fructos‐1‐yl)‐FB₁, while 23% to 37% of FB₁ species detected in extruded corn grits with and without added glucose was bound to the matrix. It was also found that the hydrolyzed form of FB₁ was a minor species in extruded corn grits with or without added glucose, representing <15% of the total FB₁ species present. Less than 46% of FB₁ originally present in corn grits could be detected in the fumonisin analogues measured in this study. Research is needed to identify the reaction products resulting from extrusion processing of fumonisin‐contaminated corn products. Practical Application: Twin‐screw extrusion is widely used in food industry for its versatility. This technology may reduce the level of fumonisins in corn particularly with added glucose.     

Effect of Pre-Treatments on Mechanical Oil Expression of Soybean Using a Commercial Oil Expeller

The effect of expeller screw press and pre-treatments on the quality and quantity of soybean oil and cake was studied using a commercial oil expeller. The pretreatments included whole soybean crushing, soy grits crushing, and crushing of soy grits extruded at 135°C. The screw speeds were 28, 35, and 45 rpm. The moisture content of soybean used in the experiment was 10% wet basis. The average capacity of the oil expeller was found to be 145 kg/h, 110 kg/h, and 120 kg/h for whole, grits, and extrudate, respectively at 45 rpm. The average capacity of oil expression from whole soybean did not vary significantly from 28 to 45 rpm. In the case of soy grits, however, the capacity was higher when the expeller speed was lowest, i.e., 28 rpm. In the case of extrudate, even in a single pass, the recovery was higher, i.e., to 71% at both 45 and 35 rpm. The color of oil from soy grits was lighter followed by extrudate, and the color of oil obtained from whole soybean was dark. The FFA in oil from all the samples was below 1%, however the lowest percentage was for oil obtained from extrudate at 0.5%. The urease activity of the extruded cake was 0.15 pH units, and the protein and oil content were about 48% and 5%, respectively. The optimum process variables for mechanical expelling of soybean were found to be extrusion as a pretreatment and speed of expeller screw at 45 rpm, which yielded throughput capacity 103 kg/h, oil recovery of 70.5%, and urease activity of the cake at 0.15.     

Stability of mycotoxins during food processing

The mycotoxins that commonly occur in cereal grains and other products are not completely destroyed during food processing operations and can contaminate finished processed foods. The mycotoxins most commonly associated with cereal grains are aflatoxins, ochratoxin A, fumonisins, deoxynivalenol and zearalenone. The various food processes that may have effects on mycotoxins include sorting, trimming, cleaning, milling, brewing, cooking, baking, frying, roasting, canning, flaking, alkaline cooking, nixtamalization, and extrusion. Most of the food processes have variable effects on mycotoxins, with those that utilize the highest temperatures having greatest effects. In general the processes reduce mycotoxin concentrations significantly, but do not eliminate them completely. However, roasting and extrusion processing show promise for lowering mycotoxin concentrations, though very high temperatures are needed to bring about much of a reduction in mycotoxin concentrations. Extrusion processing at temperatures greater than 150 degrees C are needed to give good reduction of zearalenone, moderate reduction of alfatoxins, variable to low reduction of deoxynivalenol and good reduction of fumonisins. The greatest reductions of fumonisins occur at extrusion temperatures of 160 degrees C or higher and in the presence of glucose. Extrusion of fumonisin contaminated corn grits with 10% added glucose resulted in 75-85% reduction in Fumonisin B(1) levels. Some fumonisin degredation products are formed during extrusion, including small amounts of hydrolyzed Fumonisin B(1) and N-(Carboxymethyl) - Fumonisin B(1) and somewhat higher amounts of N-(1-deoxy-d-fructos-1-yl) Fumonisin B(1) in extruded grits containing added glucose. Feeding trial toxicity tests in rats with extruded fumonisin contaminated corn grits show some reduction in toxicity of grits extruded with glucose.     

Reduced toxicity of fumonisin B1 in corn grits by single-screw extrusion

Corn grits spiked with 30 microg/g fumonisin B1 and two batches of grits fermented with Fusarium verticillioides (batch 1 contained 33 microg/g, and batch 2 contained 48 microg/g fumonisin B1), which were extruded by a single-screw extruder with and without glucose (10%, dry weight basis) supplementation were fed to rats. Control groups were fed uncontaminated grits. Extrusion with glucose more effectively reduced fumonisin B1 concentrations of the grits (75 to 85%) than did extrusion alone (10 to 28%). With one exception, the fumonisin B1-spiked and fermented extrusion products caused moderately severe kidney lesions and reduced kidney weights, effects typically found in fumonisin-exposed rats. Lesions in rats fed the least contaminated grits (batch 1) after extrusion with 10% glucose were, however, significantly less severe and not accompanied by kidney weight changes. Therefore, extrusion with glucose supplementation is potentially useful for safely reducing the toxicity of fumonisins in corn-based products and studies to determine the optimal conditions for its use are warranted.     

Effects of High Pressure Disintegration of Steeped Maize Grits on the Release of Starch Granules from the Protein Matrix

The horny endosperm of maize gives the greatest resistance to the mechanical disintegration of the protein matrix during starch extraction. Thus attempts were made to release the starch by wet-milling of maize grits in the valve of a high-pressure homogenizer. At the same time, information was gathered on the principles involved in the structural breakdown of the endosperm components. For this purpose the influence of the valve geometry as well as the concentration and flow rate of the suspension on the particle size reduction and disintegration was examined. Using a valve specially constructed for the photographic documentation of this process step, it could be shown that the slit height of the valve predominantly determined the particle size of the wet milled product. Already after a single passage through the valve, set at slit heights between 200 and 600 μm, 70% of the grits were reduced to particles <40 μm. The grits were initially between 250 and 1000 μm in size. Scanning electron microscope photographs showed that a large fraction of the mass existed as free starch granules alongside partly intact particles of the protein matrix. Since the starch granules were of higher purity after raffination, it is assumed that the extent to which disintegration of the endosperm particles results in starch granules and protein particles as separate entities, depends not only on the particle size reduction step, but also on the different visco-elastic behaviour of the protein matrix and the starch granules under the influence of the large shear forces occuring in the valve.     

Instant flour from quality protein maize (Zea mays L). Optimization of extrusion process

Traditional nixtamalization process for producing instant flours is highly time and energy consuming; in addition, it presents problems of high liquid waste discharges (3–10 L H₂O/kg maize). Extrusion represents an alternative technological for producing instant flours and does not generate effluents. The objective of this work was to determine the best combination of extrusion process variables for the production of instant flour from quality protein maize (QPM) (Zea mays L) V537 variety. Prior to extrusion, the maize kernels were broken to obtain grits (1−2 mm) which were mixed with lime and water to reach a moisture content of 28 g/100 g. The single screw extruder operation conditions were selected from a factorial combination of process variables: extrusion temperature (ET, 70–100°C), lime concentration (LC, 0.1–0.3 g/100 g maize) and screw velocity (SV, 30–80 rpm). A central composite experimental design with five variation levels was chosen. Response surface methodology was applied as optimization technique, over four response variables: in vitro protein digestibility (PD), total color difference (ΔE), water absorption index (WAI) and pH. Predictive models for response variables were developed as a function of process variables. The conventional graphical method was applied to obtain maximum PD, WAI, pH and minimum ΔE. Contour plots of each of the response variables were utilized applying superposition surface methodology, to obtain three contour plots for observation and selection of a superior (optimum) combination of ET (79.4°C), LC (0.24 g/100 g maize) and SV (73.5 rpm) to obtain optimized extruded maize flour (EMF) from QPM with a single screw extruder. Optimized EMF had similar physico-chemical and functional characteristics than commercial nixtamalized maize flours (NMF).     

Amylose and Protein Contents of Rice Cultivars as Related to Texture of Rice-based Fries

Mixtures of short-, medium-, and long-grain rice flours, defatted rice bran, salt, and water were extruded and fried to produce French fry-like products. Amylose and protein correlated positively with instrumental measures of hardness and gumminess. Water contents of frozen and fried fries correlated negatively with hardness and gumminess. Low protein rice cultivars retained more water than high protein cultivars during extrusion followed by cooling. Amylose content correlated negatively with water content of fried fries. Fries formulated from waxy rice had hardness and gumminess comparable to commercial French-fried potatoes, but all other fries were too hard and gummy.     

Fusarium mycotoxins in milling streams from the commercial milling of maize imported to the UK,and relevance to current legislation

A study in three large commercial UK maize mills showed that Fusarium mycotoxins, such as deoxynivalenol, zearalenone and fumonisins present at mill intake, are distributed in milling streams approximately according to their occurrence in the maize seed structure. Fractions derived from the endosperm tended to contain the lowest levels of mycotoxins. Concentrations of mycotoxins within the endosperm are also related to the particle size. However, the products derived from the embryo or outer seed layers contained the highest mycotoxin levels being concentrated up to five times or more, although these components are normally used for animal feed or industrial use. The general pattern of mycotoxin distribution found when milling French and Argentinean maize was similar, although very variable, and it is concluded that this variability stems from different milling strategies used at each mill and from the nature and condition of each consignment of maize. Mycotoxins in maize grits (particle sizes >500 µm) were usually reduced by the greatest amount when compared with the whole maize, while flour (≤500 µm) could be both reduced or increased depending on the mill and consignment. Thus, in most situations mycotoxin concentrations in whole maize that meet European Commission legislation on intake should give rise to levels in milled ingredients that should also do so. However, this was not always true in some ingredients, especially for fumonisins in those fractions with particle size ≤500 µm.     

Effects of particle size and moisture content of maize grits on physical properties of expanded snacks

The main aim of this research was to investigate the effects of simultaneous changing of maize grits particle size and moisture content on some physical properties and microstructure of the expanded snacks produced by an industrial single screw extruder. Maize grits with different particle sizes of 212–299, 300–474, 475–680, 681–870, 871–1,016, and 1,017–1,070 μm and various moisture contents of 15, 16, 17, and 18% were used to manufacture puffed products. The samples produced with larger particle sizes and higher moisture content exhibited lower water absorption and water solubility indices and less expansion and crispiness than other samples. As microstructure results revealed, these samples showed more uneven surface and thicker cross‐section. Overall, controlling both moisture content and particle size of maize grits had significant effects on the quality of the snacks. However, the impact of changing particle size on the snack properties was greater than changing the moisture content. This research has implications in food industry in production of puffed snacks using extrusion process. The results provide practical and green methods of improving the quality of the snacks by choosing the appropriate feed particle size and moisture content. The approach introduced in this paper is easy to impediment in the food industry without the need to change extruder configuration or adding to the list of ingredients and additives.     

Extrusion studies of mixtures containing certain meat offals: Part 2-textural properties

Thermoplastically extruded products prepared from soy grits alone, and from those containing 20% or 35% of bovine or porcine offal, at various temperatures of extrusion, were subjected to instrumental texture profile analysis (hardness, elasticity, cohesiveness, gumminess, chewiness) and shear force measurements. The offal sources were untreated, or alkali-extracted, protein from bovine and porcine lung and bovine tripe (rumen and reticulum) and protein in extracted by sodium dodecyl sulphate (SDS) from bovine tripe. For products prepared from soy grits alone, hardness, gumminess, chewiness and shear force showed maxima at 170°C, whereas elasticity and cohesiveness increased progressively in the temperature range studied (140-190°C). Products containing SDS-extracted tripe protein required more force to shear, and were more hard, gummy and chewy, than products containing untreated offal, and values for all parameters were greater in the latter than in products containing alkali-extracted offal protein. The effect of extrusion temperature on the textural parameters of the products was less than that due to the mode of offal preparation used (untreated, alkali- or SDS-extracted) or the level of incorporation. Offal source was relatively unimportant. Products containing alkali-extracted offal protein had poor internal structure and were brittle; those containing SDS-extracted protein were tough. The different textural properties of the extracted products might determine their relative suitability for use either alone, as analogues or as extenders.     

Effects of endosperm hardness and extrusion temperature on properties of products obtained with grits from two commercial maize cultivars

Two maize-grit samples obtained from a dent and a flint type of maize, having NIR hardness values of 300 and 546, respectively, were extruded at two different temperatures, 150 and 180°C and at a moisture content of 15 g moisture/100 g sample using a Brabender 10DN extruder. Expansion and cooking degrees were determined. Mechanical resistance of samples at different water activities was evaluated taking the area under the compression force-deformation curve. The triangle test was used to determine the differences in texture among samples. The results showed that expansion and cooking degrees were higher for flint maize samples. Mechanical test indicated that area values of dent maize samples were significantly higher than the ones corresponding to flint maize, in all cases. Also, the effect of temperature was significant, particularly for samples at a_w between 0.23 and 0.43. Sensory evaluations for texture were in agreement with those of the mechanical ones. The results of this research allow us to conclude that flint maize, being harder than dent maize, gives greater expansion values with higher degree of cooking and lower mechanical resistance, which means a better texture, thus supporting the preference of the snack industry for flinty maize grits. It is worthy to note that the difference in hardness shown by the maizes under study is normally found among commercial cultivars.     

Flavonol profile of cactus fruits (Opuntia ficus-indica) enriched cereal-based extrudates: Authenticity and impact of extrusion

In previous studies, it was hypothesized that isorhamnetin glycosides are the dominant flavonol derivatives occurring in the peels and cladodes of cactus Opuntia ficus-indica fruits and might be used as markers for analyzing the authenticity of food products containing (whole) cactus fruits or cladodes. In the present work, use of the whole yellow-orange fruit from cactus O. ficus-indica as an ingredient of rice- and corn-based snacks was evaluated. The impact of extrusion cooking on the flavonol profile was characterized in rice- and corn-based extruded products fortified with a freeze-dried preparation from the whole cactus fruit. HPLC analysis showed that the flavonol profile of cactus O. ficus-indica consisted of five prominent isorhamnetin glycosides with a concentration of 148.9 μg/100 mg dw. In contrast, the rice or corn grits used in the present study did not contain any flavonol at all. The freeze-dried fruit was added in different ratios (0, 2, 6, and 10%) to the rice or corn grits prior to the extrusion process. Analysis of the final extrusion products showed that flavonol profiles from the fortified rice or corn products, even at the lowest level of addition (2%), were similar to the original profile of the fruit before processing. Furthermore, the total flavonol content in extruded products was not significantly affected by extrusion cooking. This study showed that the unique flavonol profile of fruits from cactus O. ficus-indica might serve as a biochemical marker for the evaluation of the authenticity of products made from whole cactus fruit or the fruit's peel.     

Effect on protein digestibility of different processing conditions in the production of fish meal and fish feed

The effect of processing conditions on protein digestibility and fluorodinitrobenzene (FDNB)‐reactive (available) lysine in the production of fish meal and extruded fish feed has been studied under pilot and commercial conditions using mink as model animals. Fish meal produced under pilot‐plant conditions at processing temperatures below 70–80 °C (FM1) had protein digestibility of 929 (grams of protein digested per 1000 g protein consumed) compared with 905 when processed at temperatures above 100 °C (FM2). A low‐temperature‐processed commercial fish meal (CFM1) had protein digestibility of 940 compared with 888 for a standard commercial fish meal (CFM2). Pilot‐produced extruded fish feed had protein digestibility of 913 when based on FM1 as the main protein source (95% of total protein) compared with 892 when based on FM2. Commercial extruded fish feed had protein digestibility of 912 when based on CFM1 compared with 871 when based on CFM2. Varying extrusion conditions at the pilot scale, ie temperatures from 100 to 126 °C and moisture contents from 21 to 12%, did not affect protein digestibility. Similarly, under commercial conditions, variation in temperature from 89 to 110 °C and moisture from 24.5 to 19.5% did not affect FDNB‐reactive lysine and protein digestibility. The FDNB‐reactive lysine content and protein digestibility of the extruded feed were less than the values calculated from the ingredient mixture before extrusion. Thus, despite different extrusion conditions not giving different FDNB‐reactive lysine and protein digestibility, the total process, ie extrusion, drying and oil coating, caused a reduction. Copyright © 2003 Society of Chemical Industry     

Extrusion behaviour of grits from flint and sweet corn

Studies were conducted to investigate the effect of feed moisture, extrusion temperature and screw speed on the extrusion behaviour and product characteristics of flint and sweet corn grits. The extruder die pressure and extrudate properties, such as expansion and water solubility index (WSI), were analyzed. Second order polynomials were computed to describe the extruder response and product properties of grits from both corn types as a function of feed moisture, extrusion temperature and screw speed. Among feed moisture, extrusion temperature and screw speed, feed moisture showed the most pronounced effect on die pressure, expansion and WSI. Die pressure of the extruder was significantly greater for sweet corn than flint corn grits. The grits from both the corn types differ significantly with respect to extrusion behaviour and product characteristics under similar extrusion conditions. The particle size distribution revealed that flint corn grits had more fine and opaque particles and resulted in extrudates with lower WSI and expansion than those from sweet corn grits which had fewer fine particles.