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.     

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.     

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.     

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.     

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.     

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.     

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.     

Determination of formulation and processing factors affecting slowly digestible starch,protein digestibility and antioxidant capacity of extruded sorghum–maize composite flour

High‐temperature high‐pressure extrusion of sorghum–maize composite flour, of potential for healthy food manufacture, was investigated by factorial experimental design to determine the effect of level of sorghum in dry mix (15–60%); final barrel zone temperature (120–150 °C); total moisture in barrel (21.4–25.8%); total input rate (2.3–6.8 kg h^?1); and screw speed (250–450 rpm) on extrudate slowly digestible starch (SDS), phenolic content, antioxidant capacity, protein digestibility, density and expansion ratio. Extrudate SDS increased with increasing sorghum level and decreased as the barrel temperature increased. Total phenolic content and antioxidant capacity were positively associated with sorghum level. Protein digestibility was associated negatively with sorghum level and positively with barrel temperature. Extrudate density was associated positively with total moisture and negatively with barrel temperature and input rate. Sorghum in dry mix, final barrel zone temperature and total moisture in barrel were the three most significant independent variables influencing extrudate dependant variables.     

EFFECTS of FEED MOISTURE and BARREL TEMPERATURE ON the RHEOLOGICAL PROPERTIES of EXTRUDED COWPEA MEAL1

Decorticated cowpea meal was adjusted to 20, 30, and 40% moisture and extruded in a Wayne pilot-scale extruder at barrel temperatures of 150, 175 and 200°C. the resulting products were subjected to rheological evaluation using the Instron Universal Testing Machine equipped with standard tensile jaws, the Warner-Bratzler shear device and the Kramer Shear Press. Regression equations relating rheological properties to feed moisture and barrel temperature were computed from the data, and response surfaces were generated from these models. Tensile strength of extrudates was greatest for the dense products produced in the low moisture-low temperature region and declined at higher moistures and temperatures. Shear strength as determined by either the Warner-Bratzler or Kramer devices exhibited a ridge of high values extending from 20%-150°C to 30%-200°C, and declined for brittle, expanded products made at low moisture and high temperature and for soft products made at high moisture.     

Enzymatic Starch Hydrolysis of Extruded Potato Peels

Potato peels discarded by potato processors are a potential source of dietary fiber and starch. This starch may be hydrolyzed for fermentation to value-added products. Dried steam peels were extruded at 135°C and 22% feed moisture and digested with α-amylase and/or amyloglucosidase. Two barrel temperatures and feed moistures were also studied. Glucose was measured colorimetrically at O,1,2,4,8 and 24h of incubation. All peels treated with either no enzymes or α-amylase alone produced minimal glucose. Nonextruded peels digested with both enzymes produced more glucose than did those treated with amyloglucosidase alone. Complete digestion of starch occurred in extruded peels digested with amyloglucosidase, but not when α-amylase was used.     

Extrusion of Maize–Cowpea Blends in a Modified Oil Expeller

A laboratory oil expeller was modified by using a press cylinder without openings for expelling the oil. Central composite rotatable design for k=3 was used to study the effects of process variables, cowpea level (0–25%), feed moisture (10–25%) and barrel temperature (130–200°C) on product indices (moisture, expansion index, bulk density, water absorption, extractable solids, swell volume and the degree of gelatinisation of flour from the extrudate). Regression models developed to predict product indices were significant and showed no significant lack of fit. The model for moisture content of the extrudate had an R² of 0·98. Product moisture was influenced by the amount of cowpea in the feed, the temperature of extrusion and feed moisture. Furthermore, the product moisture measured at each cowpea level was dependent on the temperature of extrusion. The model for product expansion index showed that this index decreased with feed moisture and the cowpea level. Regression models for bulk density, water absorption, extractable solids and the maximum swell volume of flour from the extrudate were influenced by the process variables. The degree of gelatinisation decreased with cowpea level and increased with extrusion temperature. © 1997 SCI.     

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.     

Functional properties of corn and corn–lentil extrudates

Functional properties of corn and corn–lentil extrudates were investigated as a result of extrusion conditions, including feed rate (2.5–6.8 kg/h), feed moisture (13–19% wet basis) and extrusion temperature (170–230 °C). Lentil was used in mixtures with corn flour at a ratio of 10–50% (legume/corn). The water absorption index of extrudates increased with extrusion temperature and feed moisture content and decreased with feed rate and lentil/corn ratio. The water solubility index of extrudates increased with temperature, but decreased with feed moisture content and feed rate. The oil absorption index of extrudates increased with extrusion temperature and decreased with feed rate, feed moisture content and lentil/corn ratio. Generally, the use of lentil flour led to products with lower values for functional properties. Principal component analysis of functional properties discriminated samples with appropriate functionality based on industrial use.     

Effects of extrusion conditions on secondary extrusion variables and physical properties of fish, rice-based snacks

A formulation containing rice flour, fish powder, menhaden oil and vitamin E was extruded at a feed rate of 10 kg/h using a co-rotating twin-screw extruder. Primary extrusion (independent) variables were temperature (125-145 °C), screw speed (150-300 rpm) and feed moisture (19-23 g/100 g db). Response surface methodology (RSM) was used to study the effects of extrusion conditions on secondary extrusion variables (product temperature, pressure at the die, motor torque, specific mechanical energy input and mean residence time) and physical properties of the extrudates. Second-order polynomial models were computed and used to generate contour plots. Increasing feed moisture and screw speed decreased pressure at the die. Increased screw speed increased product temperature at the die but increased feed moisture lowered it. Increased barrel temperature, feed moisture and screw speed decreased motor torque. Increased screw speed increased specific mechanical energy, while increased feed moisture reduced it. Longer mean residence times were observed at lower screw speeds. Product density increased as feed moisture increased, but decreased with screw speed. Increased feed moisture decreased radial expansion.     

Effects of Feed Composition, Feed Moisture, and Barrel Temperature on the Physical and Rheological Properties of Snack-like Products Prepared from Cowpea and Sorghum Flours by Extrusion

Decorticated meals made from grain sorghum and cowpeas and 33-67% blends of the two were hydrated to 20.5, 23.0, and 25% moisture and extruded at 175°, 190°, and 205°C. Effects of composition, feed moisture, and barrel temperature on product temperature, residence time, expansion ratio, unit bulk density, product moisture, Warner-Bratzler shear force, stress and energy and sensory hardness and brittleness were determined. Most properties could be described by a generalized second order model. Individual models differed widely; however, composition (or its interaction terms) was significant in most cases in which it was a variable. Considering all compositions, temperature was most often significant. Effect of moisture was more significant as the proportion of cowpea in the mixtures increased. Textural properties were compared to those of three commercial snack foods. Experimental extrudates were somewhat tougher than commercial snacks although not drastically different from them.     

Influence of process and product variables on extrusion energy and pressure requirements

Energy and pressure requirements for processing foods as affected by product moisture content and extruder barrel temperature and screw speed were studied using corn gluten meal (CGM) processed in a C.W. Brabender laboratory single-screw cooker-extruder. The extruder screw was 1·9 cm in diameter, had a 3:1 compression ratio and a 20:1 barrel length-to-diameter ratio. The die-end nozzle was 3 mm in diameter. Moisture contents were 14, 20 and 26% (dry basis), extruder barrel temperatures were 120, 145 and 170°C and the extruder screw speeds were 100, 150 and 200 rpm. Regression analysis showed that moisture content contributed most to the variation in energy requirements (32·4%), followed by temperature (12·4%). Effect of screw speed was found to be insignificant. Increasing moisture content and barrel temperature caused specific energy to decrease. Pressure was found to be significantly affected and decreased with increases in all three variables.     

新型鲜湿方便米粉二级挤压工艺的研究

研究新型鲜湿方便米粉二级挤压工艺,考察生产过程中挤压关键参数(进料水分、喂料速度、一级机筒温度、二级机筒温度、模板孔径)对米粉品质的影响。实验以籼米(川种优3877)与粳米(隆两优534)为原料,利用响应面实验优化二级挤压工艺关键参数。结果表明,挤压参数能在一定范围内提高鲜湿方便米粉的品质。通过最佳二级挤压参数(进料水分41%、喂料速度0.50 kg/min、一级机筒温度179℃、二级机筒温度58℃、模板孔径1.0 mm)制作鲜湿方便米粉产品米香浓郁、富有弹性,综合品质较好。本研究可为鲜湿方便米粉连续化工业化生产提供参考。     

Gelatinization and Liquefaction of Starch with a Heat Stable α-Amylase

Sweet potato and corn starches were gelatinized and liquefied to dextrose equivalent (DE) 10 in a steam-jacketed kettle or in a twin-screw extrusion cooker in a single step process with a heat stable ex-amylase. The time required to gelatinize and liquefy 20% starch slurries in a kettle at 95°C was 45 to 50 sec. Starch powder (10 kg/hr) and water (2-6 kg/hr) were fed to an extrusion cooker to adjust the moisture contents of the starch from 20 to 55% (wet basis) and gelatinized and liquefied to DE 10 at a barrel temperature of 120°C or above with 2 to 3% (w/w) a-amylase added. The optimum conditions for the operation were to feed starch with water to maintain 50% moisture and 2% heat stable a-amylase at a barrel temperature of 120°C.     

Physicochemical properties of extruded germinated wheat and barley as modified by CO2 injection and difference extrusion conditions

Germinated wheat and barley were extruded with a pilot‐scale corotating twin‐screw extruder under different barrel temperatures (100 and 120 °C), feed moisture content (30 and 35%) and CO₂ injection. The effect of germination, barrel temperature, feed moisture content and CO₂ injection on physical properties, proximate composition, γ‐aminobutyric acid, β‐glucan, phytic acid and protease activity was investigated. Results indicated that the barrel temperature, moisture content and CO₂ injection significantly affected water absorption index (WAI), water‐soluble solid index (WSI), specific length, expansion ratio, bulk density, mechanical properties and colour of all extruded products (P < 0.05). Extrusion process significantly decreased γ‐aminobutyric acid and protease activity in extruded germinated wheat (EGW) and barley (EGB) products (with and without CO₂ injection). However, extrusion process (with and without CO₂ injection) increased β‐glucan in EGB and decreased phytic acid in EGW. The content of proximate composition, γ‐aminobutyric acid, β‐glucan, phytic acid and protease activity was slightly affected by CO₂ injection.     

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.