Critical factors in microwave expansion of starchy snacks

Microwave-mediated formation of lotus-seed starch-palmitic acid complexes and their multi-scale structural changes

Recent studies have revealed that starch-lipid complexation can significantly impact gut health via the formation of V-type resistant starch. This study used varying microwave (MW) power levels (600, 700, 800, 900, 1000 W) to prepare V-type lotus-seed starch (LS)-palmitic acid (PA) complexes and investigates their multi-scale structural and thermal properties. The results indicate that MWs promote hydrophobic LS-PA complexation to form a B + V6II-type crystalline structure, with the V-type complexation rate found to positively correlate with MW power. Specifically, a higher MW power is more conducive to guiding the evolution of the disordered structure in the complex system back to the ordered arrangement and enhancing the crystallinity and stability of the system. The evolution of this V-type crystallization process peaks at an MW power of 1000 W MW to afford a complexing index of 55.409 %. Further thermal-property analyses reveal that the V-type complexed starch is mainly arranged as highly thermally stable accumulated single-helix structures that dissociate at 100-105 °C. These findings provide valuable data for regulating V-type complex formation through MW treatment and establish a theoretical foundation for precisely designing healthy starch-based foods.

Popcorn quality parameters and nutritional properties of oily maize (Zea mays var. 'Everta') hybrids subjected to different thermal treatments

This research assessed the popcorn quality parameters and nutritional properties of 5 oily maize (Zea mays var. 'Everta') hybrids under several thermal treatments (hot air, microwave, and wet cooking). Grains contained 2.16-4.51 % crude fat and 11.08-12.94 % protein, displayed a similar amount of individual p-coumaric and ferulic acid derivatives (p > 0.05) (free: 3.61-40.53 μg/g; bound: 1621.75-1970.94 μg/g), and total phytosterols ranging from 8.76 to 13.17 μg/g. Hot air- and wet cooking-treated grains showed the highest expansion volume (121.5-133.1 mL), and there were no differences in yield and residual percentage (p < 0.05). PCA analysis clustered samples 1 and 3 as the most influential on bound phenolics, expansion time, yield, and popped grains weight, mostly under hot air and wet cooking treatments. Spearman's correlations outlined the potential of the grains' total and bound phenolics on popping quality (weight and expansion time: 0.50-0.90). Results suggested the oily hybrids' nutritional potential and suitability to produce high-quality popcorn.

Effect of microwave-puffed on Auricularia auricula polysaccharide and probiotic fermentation on its biotransformation and quality characteristics during storage period

In this study, probiotics with superior fermentation performance were screened, and the mixed-bacteria fermentation was carried out with Auricularia auricula treated with microwave-puffed process as fermentation substrate, and the changes in nutritional quality under different storage conditions were investigated. The results showed that the acid and bile salt resistance of Lactiplantibacillus plantarum 21,801 and 21,805 reached 95 % and 75 % respectively, and the intestinal adhesion was superior; microwave puffing treatment had the highest retention rate of A. auricula polysaccharides and the lowest loss of polyphenols, and no effect on soluble protein. Mixed bacterial fermentation significantly increased the total polyphenols and total flavonoids of A. auricula (p < 0.05), and the DPPH and ABTS radical scavenging reached 48.31 % and 73.21 % respectively. Furthermore, the viable counts, DPPH radical scavenging, color, and sensory quality of fermented A. auricula remained stable when stored at 4 °C. In contrast, when stored at 25 °C for 7 days, the taste was unfavorable, undesirable odor and spoilage occurred; by 21 days, DPPH clearance rate dropped below 40 % and color changed significantly (△E > 2). In conclusion, the probiotic mixed fermentation and storage conditions had a significant effect on the biometabolic transformation of macromolecules and other substances in A. auricula.

Effects of explosion puffing on the native structural organization and oil adsorption properties of starch

The effects of explosion puffing (EP) on the native structural organization (i.e., thermal properties, crystalline structure, short-range order, granule morphology and powder properties) and oil adsorption properties of puffed starch (PS) were investigated. The results showed that EP treatment could decrease the melting enthalpy of starch double helices and increase the V-type crystallinity. The highest V-type crystallinity (24.7 %) was obtained when the puffing pressure was 0.4 MPa and the starch:ethanol:water ratio was 1:2:1 (w/w). By controlling the puffing conditions, EP treatment can alter the morphology, and increase the particle size, flowability and specific surface area of PS. The high amorphous proportion and porous sheet structure of PS resulted in the highest oil adsorption capacity when the starch:ethanol:water ratio was 1:1:1 (w/w). Pearson correlation analysis showed that oil adsorption capacity was significantly and positively correlated with the 1022/995 cm-1 value and V-type crystallinity, but negatively correlated with bulk density and angle of repose. Furthermore, oil retention capacity was strongly dependent on V-type crystallinity. These findings demonstrated that EP is an innovative technology with the potential to enhance the V-type crystallinity and adsorption performance of starch.

Development of Cellular High-Protein Foods: Third-Generation Yellow Pea and Red Lentil Puffed Snacks

This study aimed to evaluate how extrusion cooking conditions and microwave heating play a role in enhancing physical and thermal properties of third-generation expanded cellular snacks made from yellow pea (YP) and red lentil (RL) flours for the first time. Increasing temperature and moisture content during extrusion resulted in darker, crunchier and crispier products with higher expansion index (EI). Microwave heating after extrusion led to an increase in cell size and porosity of YP and RL products when qualitatively compared to extrusion alone. Additionally, extrusion followed by microwave heating resulted in extensive damage to starch granular structure and complete denaturation of proteins. Using microwave heating, as a fast and inexpensive process, following partial cooking with extrusion was demonstrated to greatly improve the physical and thermal properties of YP and RL snacks. Microwave heating following mild extrusion, instead of severe extrusion cooking alone, can potentially benefit the development of high quality nutritionally-dense expanded cellular snacks made from pulse flours.

Formation of texture quality of raspberry snack under microwave puffing

Raspberry snack, as a novel berry product, has rich favor and high crisp taste, where controllable texture quality is conducive to the palatability of the snack. Determinative factors of microwave puffing in microwave intensity and duration and key property of material in Young's modulus were introduced to investigate the formation of texture quality of berry snack under microwave puffing. The results indicate that the microwave intensity has negative correlation with Young's modulus of raspberry chips, which causes the more porosity inside under microwave puffing. Reasonable Young's modulus of raspberry chips enhances the interior porosity and exterior expansion volume of raspberry snack due to the water vapor wrapped other than escaped. The greater microwave intensity results in the higher volume expansion of raspberry chips, in which the great volume expansion from porous pores structure confers moderate hardness. In microwave puffing, the formation of hardness and crispness of raspberry snack depend on microwave puffing parameters, leading to high temperature and great dehydration rate in quick puffing duration, in addition to Young's modulus of raspberry chips, where high dehydration rate accelerates water removal inside raspberry chips to form a harder texture with decreasing springiness, whereas low dehydration rate leads to the gentle change of springiness. Raspberry snack with uniform internal pores and regular shape forming desirable texture may be achieved under the microwave intensity of 7.5 W/g and the puffing duration of 6 min. This study indicates that high-quality raspberry snack may be achieved via controlling heating rate in microwave puffing.

Modelling Volume Change and Deformation in Food Products/Processes: An Overview

Volume change and large deformation occur in different solid and semi-solid foods during processing, e.g., shrinkage of fruits and vegetables during drying and of meat during cooking, swelling of grains during hydration, and expansion of dough during baking and of snacks during extrusion and puffing. In addition, food is broken down during oral processing. Such phenomena are the result of complex and dynamic relationships between composition and structure of foods, and driving forces established by processes and operating conditions. In particular, water plays a key role as plasticizer, strongly influencing the state of amorphous materials via the glass transition and, thus, their mechanical properties. Therefore, it is important to improve the understanding about these complex phenomena and to develop useful prediction tools. For this aim, different modelling approaches have been applied in the food engineering field. The objective of this article is to provide a general (non-systematic) review of recent (2005-2021) and relevant works regarding the modelling and simulation of volume change and large deformation in various food products/processes. Empirical- and physics-based models are considered, as well as different driving forces for deformation, in order to identify common bottlenecks and challenges in food engineering applications.

Microwave Foaming of Materials: An Emerging Field

In the last two decades, the application of microwave heating to the processing of materials has to become increasingly widespread. Microwave-assisted foaming processes show promise for industrial commercialization due to the potential advantages that microwaves have shown compared to conventional methods. These include reducing process time, improved energy efficiency, solvent-free foaming, reduced processing steps, and improved product quality. However, the interaction of microwave energy with foaming materials, the effects of critical processing factors on microwave foaming behavior, and the foamed product's final properties are still not well-explored. This article reviews the mechanism and principles of microwave foaming of different materials. The article critically evaluates the impact of influential foaming parameters such as blowing agent, viscosity, precursor properties, microwave conditions, additives, and filler on the interaction of microwave, foaming material, physical (expansion, cellular structure, and density), mechanical, and thermal properties of the resultant foamed product. Finally, the key challenges and opportunities for developing industrial microwave foaming processes are identified, and areas for potential future research works are highlighted.

Investigation of Structural Transformations During the Manufacturing of Expanded Snacks for Reformulation Purposes

In this paper, we investigate the functionality of potato-based ingredients present in indirectly expanded snacks via careful analysis of their transformation during processing. This research is driven by the desire of industry to develop similar snacks for upcoming markets, where the potato-based ingredients are replaced by other starch sources, which are locally available and at a lower cost. For a range of reformulated snacks, the transformations of starchy ingredients are analysed with a wide variety of experimental methods, like DSC, XRD, and XRT. Our analysis shows that ingredients undergo little transformations during extrusion, which is indeed intended to be mild. During frying native tuber starches (potato and tapioca starch) fully gelatinize, while cereal starches show little gelatinization and swelling. Despite the gelatinization of tuber starches, the particulate character of ingredients is retained. Replacement of pregelatinized potato starch with other starches shows little change in structure. The evolution of the structure of the reformulated snacks are analysed with the CDS formalism. We conclude that gel formers and hard fillers present in the analysed formulations had little functionality regarding texture or structure. For texture, it appears to be required that the matrix composes of a bicontinuous structure of soft fillers, namely gelatinized tuber starches and potato dehydrates. Both these ingredients can be replaced by other tuber-starch sources if the aggregation of the two soft fillers can be prevented. Commercial availability of tuber flours can still be an issue.

Impact of Processing Factors on Quality of Frozen Vegetables and Fruits

In this paper I review the production of frozen vegetables and fruits from a chain perspective. I argue that the final quality of the frozen product still can be improved via (a) optimization of the complete existing production chain towards quality, and/or (b) introduction of some promising novel processing technology. For this optimization, knowledge is required how all processing steps impact the final quality. Hence, first I review physicochemical and biochemical processes underlying the final quality, such as water holding capacity, ice crystal growth and mechanical damage. Subsequently, I review how each individual processing step impacts the final quality via these fundamental physicochemical and biochemical processes. In this review of processing steps, I also review the potential of novel processing technologies. The results of our literature review are summarized via a causal network, linking processing steps, fundamental physicochemical and biochemical processes, and their correlation with final product quality. I conclude that there is room for optimization of the current production chains via matching processing times with time scales of the fundamental physicochemical and biochemical processes. Regarding novel processing technology, it is concluded in general that they are difficult to implement in the context of existing production chains. I do see the potential for novel processing technology combined with process intensification, incorporating the blanching pretreatment—but which involves quite a change of the production chain.

Pyrolysis, morphology and microwave absorption properties of tobacco stem materials

The recent development of microwave radiation technology has increased the application possibilities of waste tobacco stems (WTSs). In this study, the morphology and microwave absorption properties of tobacco stem materials as well as the pyrolysis of the resultant biomass (BMTS) were studied via thermogravimetry-differential scanning calorimetry (TG-DSC), scanning electron microscopy (SEM), mercury intrusion porosimetry (MIP), and a vector network analysis (VNA). The results show that the BMTS pyrolysis involves four stages in air: dehydration, heat transfer, pyrolysis, and carbonisation, and it involves three stages in N2: moisture evaporation, de-volatilization, and charring. The microwave-assisted expansion of WTSs can improve the pore diameter and total porosity of the expanded tobacco stems (ETSs) and BMTS. The latter is a macroporous material with a total porosity of 78.2% and a probable pore size of 29.5 μm. Its pore size distribution ranges from 10.7 nm to 227 μm. The microwave absorption properties of the WTSs are affected by the moisture content, bulk density, and grain size; the properties can be enhanced by decreasing the grain size and increasing the moisture content and bulk density within the experimental range. The 3 dB bandwidth and amplitude vary by 0.45 MHz and - 0.406 dB per 1% increase in the moisture content of the materials, respectively. Our results demonstrate that tobacco stem materials with different moisture contents and grain sizes should be classified before the expansion or re-drying steps to ensure heating uniformity and product quality during the microwave radiation treatment.

Selected properties of the potato snacks expanded in the microwave radiation

The results of measurements of the selected properties of the extruded potato pellets and snacks expanded in the microwave field are presented in the paper. The potato pellets with the addition of the baking soda were prepared with a single screw extruder TS-45. The snacks were obtained by pellets expansion in a conventional microwave oven. The expansion index and the hardness of the pellets and the snacks, as well as, the texture properties of the snacks were evaluated during this study. The results showed that baking soda addition reduced the potato pellet expansion during their extrusion. This was an effect of a smaller thickness of the obtained pellets. The addition of baking soda had positive influence on potato snacks expansion in microwave radiation. The higher content of the soda additive resulted in lower hardness of pellets during cutting tests. The opposite effect was observed during texture measurements of the snacks. The addition of baking soda increased hardness of the expanded snacks. Soda addition lowers crispness and fragilityof the potato snacks expanded in the microwave radiation.

Shape Effect on the Temperature Field during Microwave Heating Process

Aiming at improving the food quality during microwave process, this article mainly focused on the numerical simulation of shape effect, which was evaluated by microwave power absorption capability and temperature distribution uniformity in a single sample heated in a domestic microwave oven. This article only took the electromagnetic field and heat conduction in solid into consideration. The Maxwell equations were used to calculate the distribution of microwave electromagnetic field distribution in the microwave cavity and samples; then the electromagnetic energy was coupled as the heat source in the heat conduction process in samples. Quantitatively, the power absorption capability and temperature distribution uniformity were, respectively, described by power absorption efficiency (PAE) and the statistical variation of coefficient (COV). In addition, we defined the comprehensive evaluation coefficient (CEC) to describe the usability of a specific sample. In accordance with volume or the wave numbers and penetration numbers in the radial and axial directions of samples, they can be classified into different groups. And according to the PAE, COV, and CEC value and the specific need of microwave process, an optimal sample shape and orientation could be decided.