Effect of Feed Composition, Moisture Content and Extrusion Temperature On Extrudate Characteristics of Yam-Corn-Rice Based Snack Food
Effect of Feed Composition, Moisture Content and Extrusion Temperature On Extrudate Characteristics of Yam-Corn-Rice Based Snack Food
DOI 10.1007/s13197-013-1181-x
ORIGINAL ARTICLE
Revised: 9 September 2013 / Accepted: 26 September 2013 / Published online: 11 October 2013
# Association of Food Scientists & Technologists (India) 2013
Abstract Blends of yam, rice and corn flour were processed in Keywords Yam . Extruded snack . Box-Behnken design .
a twin-screw extruder. Effects of yam flour (10–40 %), feed RSM . WSI . WAI
moisture content (12–24 %) and extruder barrel temperature
(100–140 °C) on the characteristics of the dried extrudates was
investigated using a statistical technique response surface
methodology (RSM). Radial expansion ratio differed signifi- Introduction
cantly (p ≤0.05) with change in all the independent variables.
Highest expansion (3.97) was found at lowest moisture content Yam (Dioscorea species of family Dioscoreaceae) is a multi-
(12 %) and highest barrel temperature (140 °C). Increased yam species tuber crop cultivated in Africa, Asia, parts of South
flour level decreased the expansion ratio significantly. Water America, as well as the Caribbean and the South Pacific islands
absorption index (WAI) increased significantly with increase of (Asiedu and Sartie 2010). Yams are excellent source of dietary
all variables. However, water solubility index (WSI) did not energy for most people in the developing countries (Krishnan
change with change in yam flour percent. Hardness of et al. 2010). They are rich in minerals like phosphorous,
extrudates that varied from 3.86 to 6.94 N was positively potassium, manganese and vitamins (Moorthy 1994). Yam
correlated with yam flour level and feed moisture content, tubers are consumed like the way potatoes are consumed. They
however it decreased significantly (p ≤0.001) with increase of are steamed, boiled or baked and consumed (Wanasundera and
barrel temperature. Yam percent of 15.75 with feed moisture Ravidran 1992). In West and Central Africa, yams are
and barrel temperature at 12.00 % and 140 °C respectively gave processed into dry yam tubers/slices and flour (Otegbayo
an optimized product of high desirability (> 0.90) with opti- et al. 2006; Sobukola et al. 2010). The main application
mum responses of 3.29 expansion ratio, 5.64 g/g dry solid claimed for yam flour has been in bread products and snacks
water absorption index, 30.39 % water solubility index and (Sebio and Chang 2000). Some species of yam are also
3.86 N hardness. The predicted values registered non- exploited for pharmaceutical use (Asiedu and Sartie 2010).
significant (p <0.10) differences from the experimental results. Study on yam flour making with standardized methods of
Further study would include the sensory properties enhance- drying like sun drying (Oyelade et al. 2008), hot air oven
ment of extruded snacks and little emphasis on the chemistry of drying (Alves et al. 2002), cabinet and foam mat drying
interaction between different components. (Falade and Onyeoziri 2012) have been carried out extensive-
ly, which is utilized for making extruded snacks. One potential
problem in processed flour is the discoloration and the dark-
D. Seth (*) : L. S. Badwaik
ening of the product, which may be undesirable to many
Department of Food Engineering and Technology, Tezpur
University, Napam, Tezpur, Assam 784028, India people (Onayemi 1986; Sobukola et al. 2008). This has been
e-mail: [email protected] attributed to browning reactions as a result of the presence of
L. S. Badwaik water-soluble phenolic substances (Mathew and Parpia 1971).
e-mail: [email protected] Cereal and snack food industries have successfully adopted
extrusion technology which is considered as one of the most
V. Ganapathy
economic process (Harper and Clark 1979). Extruded foods
Department of Food Processing and Engineering, Karunya
University, Coimbatore, Tamil Nadu 641114, India are composed mainly of cereals, starches, and/or vegetable
e-mail: [email protected] proteins. The major functions of these ingredients are to give
J Food Sci Technol (March 2015) 52(3):1830–1838 1831
texture, structure, mouth feel, bulk, and many other character- Preparation of flours and blending Yam tubers (D. alata)
istics desired for specific finished products (Launay and Lisch were washed and steam blanched at 90 °C for 20 min for easy
1983). These characteristics are quantified by functional prop- peeling of the outer thick skin thereafter. Peeled yam tubers
erties like bulk density, expansion index, water absorption and were cut into slices (2 cm thick) and mashed to paste before
solubility indices and viscosity of the product (Singh et al. drying to moisture content of less than 5 % (w.b.). Dried yam
2007; Oikonomou and Krokida 2011). The effects of extru- flakes were ground to powder in a Hammer mill (Alfa Instru-
sion conditions and feed compositions on functional proper- ments, Delhi, India) and sieved through a 40 mesh screen to
ties of various cereal and pulse based products have been obtain yam flour. Rice and corn grits were cleaned and dried
studied extensively (Balasubramanian et al. 2012; Seth and before milling in Hammer mill. The analysis of chemical com-
Rajamanickam 2012). Several studies found that increasing positions like crude protein, crude fat, crude fiber, ash and
feed moisture content increases the bulk density, water solu- moisture content of dried yam flour, rice and corn flours were
bility index, water absorption index and hardness and de- carried out by standard methods (AOAC 2000). The percents
creases the expansion ratio (Chiu et al. 2012; Kirjoranta of carbohydrates were found by deduction method. The blends
et al. 2012; Oke et al. 2012). Higher barrel temperature in- of feed ingredients were obtained according to the experimen-
creases the expansion and reduces the hardness of the tal design at three level combinations. The ratios of yam, rice
extrudates (Sebio and Chang 2000). High fiber ingredient is and corn flours were 10:40:40, 25:37.5:37.5 and 40:30:30. All
associated with low expansion of extrudates (Pai et al. 2009). the flours were mixed in a Laboratory mixer (Neoplast Engi-
Though cereal ingredients are mainly used in extrusion neering Pvt. Ltd., India). The blend moisture content was
processes from the inception of the technology, the use of determined by standard method (AOAC 2000). Before being
tubers in product formulation was seen at a later stage (Sebio processed, the blend was rehydrated to each required moisture
and Chang 2000; Hashimoto and Grossmann 2003; Chiu et al. content level (Table 1) by calculated amount of water sprayed
2012). The tubers contribute more fiber to the extruded prod- on to the feed. The blend was then kept in sealed polyethylene
ucts with added health benefits. Sebio and Chang (2000) used bags for 24 h for uniform distribution of moisture.
yam species Dioscorea rotundata to develop extruded food
product. Since, single ingredient was used in the study, Extrusion cooking process The prepared homogenous blend
extrudates gave hard texture with little expansion, attributed of yam, rice and corn flours were extruded in a co-rotating twin
to the high fiber content of the tuber. This problem was screw extruder (M/s Basic Technology Pvt. Ltd. Kolkata,
rectified by Chiu et al. (2012) using cereal ingredients in India). Experiments were performed at a screw speed of
conjunction with yam (Dioscorea alata L.) flour to make a 300 rpm and feed screw speed of 175 rpm. The barrel temper-
good textured product. However, there is a dearth of informa- ature was varied according to the experimental design at three
tion on the effect of barrel temperature on the extrudate quality levels viz. 100, 120 and 140 °C. The configurations of extruder
which uses D. alata species along with the cereal ingredients. are same as discussed by Seth and Rajamanickam (2012).
D. alata is characterized by higher dry matter, starch and
amylase content, high amylose/amylopectin ratio. Amylose/ Response surface analysis Response surface methodology
amylopectin ratio has been reported to impart definite charac- (RSM) is a multivariate equation solving technique, which
teristics and functionality to starches by determining the basic uses experimental data to fit mathematically in a theoretical
texture and nature of their products (Moorthy 1994; Scott design through a response function (Santelli et al. 2006). This
1996). There are established researches on rice and corn based technique is applied to describe the individual and interactive
extrudates with good textural and sensory attributes (Jin et al. effects of the independent variables on the response. The RSM
1995; Hanwu et al. 2005). Hence, rice and corn flours were helps in optimizing a set of operational variables of the process
taken with yam for feed formulation and see the effects of feed (Myers and Montgomery 2002). The RSM approach has wide-
composition, moisture content, and extruder barrel tempera- ly been applied in extruded food product development (Yagci
ture on the product qualities. and Gogus 2009; Oke et al. 2012; Seth and Rajamanickam
2012). Among the factorial design Central Composite Design
(CCD) and Box-Behnken Design (BBD) are the most common
designs adopted in food product development to estimate
Materials and methods response surface and subsequent optimization of the process
variables. They help to reduce the number of trials and thus the
Raw materials Wholesome, mature, dormant tubers of water time and cost of research with more realistic output. BBD is a
yam (Dioscorea alata L.) were obtained from a local market spherical, revolving design, consists of middle points of the
of Coimbatore, India and used for this investigation. De- edges of the circle, circumscribed on the sphere. BBD gives the
husked polished rice and edible corn grits were purchased matrix of relatively few trials for determining the complex
locally. response function and the trials with variable combinations of
1832 J Food Sci Technol (March 2015) 52(3):1830–1838
Table 1 Box-behnken experimental design with process variables (both coded and uncoded) and experimental results of yam-cereal based extruded
snack
Trial no. Yam flour (%) Moisture content Barrel Expansion Water absorption index Water solubility index Hardness
(% wb) temperature (°C) ratio (ER) (WAI) (g/g dry matter) (WSI) (%) (N)
highest or lowest levels simultaneously are avoided. So, it is where Y is the predicted response, β 0 the constant coefficient,
useful in avoiding experiments performed under extreme con- β i the linear coefficient, represent, β ii the quadratic coeffi-
ditions, for which unsatisfactory results might occur (Ferreira cients, β ij the interaction coefficients and X i , X j the coded
et al. 2007). The number of experimental runs required in BBD values of the process variables and ε the residual error
is N=2 K (K-1)+C 0 , where K is the number of variables and (Diamante et al. 2012). In the current study β 1 , β 2 and β 3
C 0 is the number of central points. Thus, for a three factorial are the coefficients of yam flour level, feed moisture content
design, a total of 17 experimental runs with 5 central points and barrel temperature respectively. The responses studied
were performed in this study. The levels of each independent were expansion ratio (ER), water absorption index (WAI),
variable were fixed according to preliminary trials and related water solubility index (WSI) and hardness. The goodness of
literature data. The coded (±1 and 0) and natural value of the the fit and the significance of linear, quadratic and interaction
independent variables with design matrix is given in Table 1. A effects of each factor on the responses were examined by
second order polynomial model was employed for three factor performing analysis of variance (ANOVA) (Table 3). The
design which is given as estimated regression coefficients of the coded values are
X
3 X
3 2 X
X 3 presented in Table 4. The generation of response surface plots
Y ¼ βo þ βi X i þ β ii X 2i þ β ij X i X j þ ε and statistical analysis was carried out using statistical soft-
i¼1 j¼1 i¼1 j¼1 ware Design-expert, verson-6 (Stat-ease Inc, Minneapolis,
Table 2 Proximate compositions of yam, rice and corn flours (percent on dry basis)
Moisture (%) Carbohydrate (%) Crude protein (%) Crude fat (%) Crude Fiber (%) Ash (%)
Table 3 Analysis of variance showing the linear, quadratic, interaction and lack of fit of the response variables
Expansion ratio (ER) Water absorption index (WAI) Water solubility index Hardness (N)
(g/g dry solids) (WSI) (%)
USA). The correlation coefficients (R 2 ) of the generated Expansion Ratio (ER) It was observed from the regression
models of all the response variables were more than 0.90 coefficients (Table 3) that the feed moisture content had a
and the lack of fit were non-significant at 95 % probability negative linear and positive quadratic effect, whereas the
level (p ≤0.05). barrel temperature had a positive effect in both linear and
quadratic terms (p ≤0.001). Figure 1a shows the effect of
Extrudate characteristics Expansion ratio (ER) of extrudate moisture content and barrel temperature on the ER of extruded
was measured laterally with caliper (Mitutoyo Inc, Japan) and snack. The highest value of ER was at 12 % (wb) moisture
expressed as the ratio of cross sectional area of the extrudate to content and 140 °C barrel temperature, whereas the lowest
that of the die (Chakraborty et al. 2009). ER was obtained value was found at 18 % moisture content and 100 °C barrel
from a mean of 15 random samples. WAI and WSI were temperature. Sun and Muthukumarappan (2002) extruded soy
obtained from 2.5 g sample according to the method of An- and corn flour and reported that ER increased with increase in
derson (1982). WAI (g/g dry solid) was expressed as the ratio feed moisture from 13 to 18 % and then decreased. Similar
of the weight of the gel after removal of supernatant to the dry trend was observed in this study. Oke et al. (2012) studied the
weight of the sample. The weight of dry solid in supernatant effect of moisture content on ER and concluded that decreased
expressed as a percentage of the original weight of the sample moisture content increases the drag force and therefore exerts
is the WSI. Hardness of samples was measured using Stable more pressure at the die resulting in greater expansion of
Microsystems TA-HD Texture Analyzer (Texture Technolo- extrudate at the exit. The expansion at higher barrel tempera-
gies Corp, Scarsdale, NY, USA) fitted with a 5 kg load cell. ture can be attributed to the starch gelatinization and strength-
The force (N) required for a circular probe of 35 mm diameter ening of structure (Ali et al. 1996; Ainsworth et al. 2007).
to penetrate 20 % into the bar was measured (Chiu et al. 2012). Many researchers reciprocated similar findings while devel-
oping yam based extruded products (Kpodo and Plahar 1990;
Sobukola et al. 2012).
Increasing yam flour level decreased ER significantly (p ≤
0.01) in quadratic term. The decrease in ER could be due to
Results and discussion the increased percentage of protein and fiber in the feed and
their interaction, which form complexes and render the ex-
The proximate compositions of yam flour, rice and corn grits pansion of extrudate at the die (Rampersad et al. 2003).
are presented in Table 2. The reported values are mean of Higher percentages of protein and fiber in corn might have
triplicate samples with standard deviations. hindered the expansion of extrudates. Figure 1b shows the
1834 J Food Sci Technol (March 2015) 52(3):1830–1838
3.11
3.90
3.45 2.79
Expansion Ratio
2.48
Expansion Ratio
3.01
2.57 2.17
2.12 1.86
140 140
24 40.0
130 130
21 32.5
120 120
18 25.0
Barrel Temperature (C) 110 15
Barrel Temperature (C) 110 17.5
Moisture content (% wb) Yam flour (%)
100 12 100 10.0
a b
6.14
6.36
5.92
WAI (g/g dry solid)
6.10
5.69
WAI (g/ g dry solid)
5.84
5.47
5.58
5.25
5.32
24
140
40.0
21 40.0
32.5 130
32.5
18 120
25.0 25.0
Moisture content (% wb) 15 17.5 Barrel temperature (C) 110 17.5
Yam flour (%) Yam flour (%)
12 10.0 100 10.0
c d
Fig. 1 Response surface diagrams illustrating the effects of yam flour, feed moisture and barrel temperature on (a & b) expansion ratio and (c & d)
water absorption index of extruded snack
effect of yam flour on ER. Chiu et al. (2012) developed yam observed similar relationships between WAI and fiber while
based snack and observed similar effect of yam flour level on developing cassava bran and cassava starch extrudates. Chiu
ER. et al. (2012) found increased effect of yam flour level from 10
to 30 % on WAI; however, the effect was not significant at p ≤
Water absorption index (WAI) WAI, an index of starch gela- 0.05. Many researchers (Anderson 1982; Chakraborty et al.
tinization (Anderson 1982; Singh et al. 2007) was in the range 2011; Sobukola et al. 2012) demonstrated strong relationship
of 5.23 to 6.34 g/g dry solid. The coefficient estimates of WAI of barrel temperature on WAI. In the present study, an increase
model (Table 4) showed that all the three variables had sig- in WAI was observed with increased temperature and mois-
nificant positive effect in the linear and quadratic terms. The ture content (Fig. 1c, d). At higher temperature, starch granule
effect of yam flour level on WAI is shown in Fig. 1c, d and it is disrupted and more water is bound to the starch molecule
was interpreted that increased yam flour level increases the resulting in increased WAI. Kumar et al. (2010) examined the
WAI significantly (p≤0.001). This could be due to increased increased effect of WAI with increased temperature which is
availability of fiber in the yam flour which has the higher in support of our current findings. WAI has been reported to
water absorption capacity. Hashimoto and Grossmann (2003) increase with increase in moisture content of feed (Ding et al.
J Food Sci Technol (March 2015) 52(3):1830–1838 1835
Table 4 Estimated regression coefficients of the fitted second order moisture content decreased lateral expansion due to plastici-
polynomial for response variables (coded)
zation of melt. Regression coefficients (Table 4) show that
Coefficients Estimated coefficients yam flour level did not have significant effect on WSI, though
a slight increase was observed (Fig. 2a). The WSI value is an
Expansion Water Water Hardness indication of state of protein in proteinaceous blends. Since, in
ratio (ER) absorption solubility
index (WAI) index (WSI) our blend, the proportion of protein is high, the increase might
be due to partial protein denaturation at higher temperature
β0 2.24 5.55 23.37 5.55 (Oikonomou and Krokida 2011). Kumar et al. (2010) indicat-
β1 −0.07 0.36*** 0.045 0.33* ed that WSI increases with increase in fibrous content in the
β2 −0.28*** 0.086** −0.26 0.24* feed formulation, which supports our findings (Fig. 2b).
β3 0.40*** 0.14*** 2.11*** −0.85***
β 11 −0.27** 0.16*** 0.67 −0.41* Hardness The effects of process variables on the hardness of
β 22 0.33*** 0.036 1.51** 0.23 yam extrudates are presented in Fig. 2c, d and exhibited that
β 33 0.41*** 0.15*** −0.75 0.073 increasing yam flour level and feed moisture content increased
β 12 −0.013 0.017 0.22 −0.34* the hardness of extrudate, whereas barrel temperature de-
β 13 −0.16* 0.002 −0.18 0.30 creased the hardness. Fiber in the yam flour could have
β 23 −0.23** −0.07* −3.48*** 0.16 imparted structural integrity to the extrudate due to protein-
fiber interaction, as a result higher value of hardness (Chiu
*
Significant at P ≤0.05 et al. 2012). The effect of premature gas cell rupture which
**
Significant at P ≤0.01 reduces the expansion due to fiber, was explained by Lue et al.
***
Significant at P ≤0.001 (1991). Further, Jin et al. (1995) interpreted in their findings
ns
not significant that, thickness of cell wall and smaller air cell increased
breaking strength, thus hardness. Increased moisture content
2005; Singh et al. 2007; Chakraborty et al. 2011). Lawton and increased hardness significantly at p ≤0.05 (Table 4), which
Handerson (1972) explained that, at higher moisture content, might be due to reduced expansion of the extrudate and lower
viscosity of starch would be low, allowing the starch mole- rate of starch degradation at higher moisture content. Rela-
cules to move freely and thereby enhancing the penetration of tionship between hardness and moisture content has widely
heat as a result greater gelatinization. However, Sobukola been investigated by researchers (Sebio and Chang 2000;
et al. (2012) interpreted that lower moisture content imparts Kumar et al. 2010; Chiu et al. 2012). Variation of
more shearing action in the barrel causing more mechanical hardness with the barrel temperature was prominent
damage to starch, thus low WAI. (p ≤0.001). Many researchers (Kpodo and Plahar 1990;
Sebio and Chang 2000; Kumar et al. 2010) found sim-
Water solubility index (WSI) The extrudates exhibited WSI in ilar effects of temperature on hardness. The decrease in
the range of 18.13 to 30.39 %. Barrel temperature was the hardness with increase of temperature might be due to
single most important factor that affected the WSI significant- higher expansion at elevated temperatures.
ly (p ≤0.001) (Table 4). This could be due to starch degrada-
tion at higher temperature exposure to product inside the Optimization and model verification The independent vari-
barrel and greater shearing action of the blend. According to ables were optimized numerically using statistical software
Anderson et al. (1970), it is the amount of free polysaccharides Design Expert, version- 6.0.11 (Stat-Ease Inc.). The variables
released from the starch granules after addition of excess were kept in range during optimization. The goals were
water. Sobukola et al. (2012) reported that, increased barrel assigned to each response parameters. The WAI and WSI
temperature increases WSI, due to increased solubility of were kept in range; hardness and ER were at minimum and
starch molecules. This was also in consistent with the results maximum respectively. From the numerical analysis, it was
of Ding et al. (2005). Feed moisture content had a quadratic observed that 15.75 % yam flour, 12.06 % feed moisture and
effect on the WSI (p ≤0.01). From the Fig. 2a, it can be seen 140 °C barrel temperature gave an optimized product of 0.987
that, the WSI decreased with increase in feed moisture from desirability. The corresponding optimized response values
12 to 18 %. Lower moisture content again could have found were ER 3.29, WAI 5.64 g/g dry solid, WSI
increased the drag force at the die making the starch to 30.39 % and hardness 3.86 N. Extrusion cooking was
gelatinize. Higher moisture content above 18 % might have carried out using optimum processing conditions with opti-
helped the polysaccharides to dissolve easily to the food mized blend and the responses were recorded. The response
matrix, as a result increased WSI. Ding et al. (2005) discussed values mentioned in Table 5 are the mean of five replicates
the higher lateral expansion is attributed to higher WSI at with standard deviation. To check the variability of predicted
initial increase of moisture content, but further increase in responses, two-tailed, one sample t-test was carried out. The
1836 J Food Sci Technol (March 2015) 52(3):1830–1838
25.98 29.98
25.33 27.18
24.67 24.39
WSI (%)
24.02
WSI (%)
21.59
23.36 18.79
24 140
40.0 24
21 130
32.5 21
18 120
25.0 18
Moisture content (% wb) 15 17.5 Barrel temperature (C) 110 15
Yam flour (%) Moisture content (% wb)
12 10.0 100 12
a b
6.47
5.79
6.02
5.11
Hardness (N)
5.63
4.42
5.24
3.74
Hardness (N)
4.85
4.47
140
130
24
40.0
21 120 40.0
32.5 32.5
18 Barrel temperature (C)
25.0 25.0
110
Moisture content (% wb) 15 17.5 17.5
Yam flour (%)
12 10.0 100 10.0
Yam flour (%)
c d
Fig. 2 Response surface diagrams illustrating the effects of yam flour, feed moisture and extrusion temperature on (a & b) water solubility index and (c-
d) hardness of extruded snack
results of the t -test demonstrated no significant difference responses. Thus, suitability of the models to predict various
between the values of recorded responses and the predicted responses was ascertained.
Conclusion Falade KO, Onyeoziri NF (2012) Effects of cultivars and drying method
on colour, pasting and sensory attributes of instant yam (Dioscorea
rotundata) flour. Food Bioprocess Technol 5:879–887
Designed experiments using Box-Behnken successfully exhib- Ferreira SLC, Bruns RE, Ferreira HS, Matos GD, David JM, Brandão
ited the effect of independent variables (yam flour level, barrel GC, Da Silva EGP, Portugal LA, Dos Reis PS, Souza AS, Dos
temperature and feed moisture content) on the response vari- Santos WNL (2007) Box–Behnken design: an alternative for the
optimization of analytical methods. Analytica Chimica Acta 597:
ables (ER, WAI, WSI and Hardness) of extrudates developed
179–186
from yam-rice-corn flour blend formulation. The developed Hanwu LR, Fulcher G, Ruan R, Lengerich B (2005) SME-Arrhenius
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