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Eur Food Res Technol (2004) 218:474–479

DOI 10.1007/s00217-004-0884-7

ORIGINAL PAPER

Emir Ayşe Őzer · Şenol İbanoğlu · Paul Ainsworth ·


Cahide Yağmur

Expansion characteristics of a nutritious extruded snack food using


response surface methodology

Received: 28 July 2003 / Revised: 22 December 2003 / Published online: 6 February 2004
 Springer-Verlag 2004

Abstract Response surface methodology was used to cooking plays an important role in the production of
analyze the effect of screw speed (220–340 rpm), feed snack foods as well as breakfast cereals, modified flours
moisture (11.0–15.0%, wet basis) and feed rate (22.0– and sweets [1]. Snack foods have become an important
26.0 kg/h, wet basis) on the physical properties (i.e., bulk part of the diets of many individuals including children
density, expansion, porosity) of a nutritionally balanced [2]. Cereal grains are generally used as the major raw
extruded snack food. Regression equations describing the materials in extruded snack foods. However, they tend to
effect of each variable on the responses were obtained. be low in protein and to have a poor biological value due
Responses were most affected by changes in screw speed to their limited essential amino acid contents [3]. Nutri-
followed by feed moisture and feed rate (P<0.05). tious snack foods can be produced by incorporation of
Expansion and porosity increased with screw speed and legumes, vegetables, and fruits into the formulation [2].
feed moisture whereas the opposite was observed for bulk Materials undergo a series of complex chemical and
density. Radial expansion was found to be a better index physical reactions during extrusion leading to products
to measure the extent of expansion than the axial and with different characteristics. Expansion is an important
overall expansions, indicated by a higher correlation parameter in the production of a cereal-based extruded
coefficient. snack food in terms of the functional properties of the
final product [4].
Keywords Extrusion cooking · Snack food · Expansion · The basic principle of response surface methodology is
Nutrition · Response surface methodology to relate product characteristics to process parameters
using statistical methods, yielding multivariate regression
equations. The purpose of this work was to investigate the
Introduction expansion properties of an extruded snack food that was
enriched with oat flour, chickpea, carrot powder, and
Extrusion cooking is a versatile process that combines ground hazelnut using response surface methodology.
several unit operations including mixing, shearing, con-
veying, heating, puffing and partial drying, depending on
the extruder design and process conditions. Extrusion Materials and methods
E. A. Őzer · C. Yağmur Materials. Regular corn flour (moisture 10.9%), cornstarch (mois-
Food Engineering Department, Agricultural College, ture 11.0%), enzymatically stabilized whole oat flour (moisture
ukurova University, 8.6%), raw chickpea flour (moisture 9.6%), carrot powder (mois-
Adana, Turkey ture 7.5%), and ground raw hazelnut (moisture 4.2%) were
purchased from local markets in Manchester (UK).
Ş. İbanoğlu ())
Food Engineering Department, Engineering Faculty, The extrusion system. A Werner & Pfleiderer Continua 37 co-
Gaziantep University, rotating twin-screw extruder (Stuttgart, Germany) was used to
Gaziantep, Turkey produce a nutritious snack food product. The barrel diameter and
l/d ratio were 37 mm and 27:1, respectively. A screw configuration
e-mail: sibanoglu@gantep.edu.tr that was a standard design for processing cereals and flour-based
Tel.: +90-342-360-1200 products was used. This screw profile was made up of conveying
Fax: +90-342-360-1100 self-wiping elements, except for a section consisting of short
reverse and forwarding elements to improve mixing and apply
P. Ainsworth shear to the material being extruded while restricting flow and
Department of Food and Consumer Technology, building up pressure. The exit diameter of the circular die was
Hollings Faculty, The Manchester Metropolitan University, 4 mm. A twin-screw volumetric feeder (Rospen, Gloucestershire,
Old Hall Lane, Manchester, M14 6HR, UK
475
Table 1 The composition of dry mix used in extrusion runs Overall expansion. Overall expansion was calculated as the ratio of
solids density to bulk density.
Ingredient Content (%, w/w, wet basis)
Chickpea flour 30.0 Radial expansion. Radial expansion was calculated as the average
Corn flour 20.0 cross-sectional area of the extrudates to the cross-sectional area of
Oat flour 20.0 the die orifice. A vernier caliper was used to measure the diameters
Cornstarch 15.0 of extrudates. The average resulting from ten measurements of
Carrot powder 10.0 extrudate diameter was used to calculate radial expansion.
Ground raw hazelnut 5.0
Axial expansion. This was calculated as the ratio of overall
expansion to radial expansion.

UK) was used for the dry feed mix while a variable speed peristaltic Total porosity. Total porosity (TP) was calculated using the
pump (Watson-Marlow, Type MHRE 200, Falmouth, UK) was equation:
used to inject water into the extruder barrel. TP ¼ ðbulk volume  apparent volumeÞ=bulk volume ð2Þ
Sample preparation and experimental design. The dry ingredients Bulk volume was calculated using the actual dimensions of the
were mixed in a Hobart mixer (model NCM30, London, UK) for extrudates assuming that the extrudates were cylinders. Apparent
30 min according to the composition given in Table 1. The volume was calculated from the volume of ground extrudates using
moisture, protein, fat and ash contents of the resultant dry mixture a graduated cylinder as described before.
were 10.5, 15.2, 7.2 and 1.9%, respectively. The temperature of the
extruder barrel was kept constant at 110 C. The extrudates were
cut by hand using a sharp knife (approximately 40 cm long) as they
emerged from the die and left to cool at room temperature for about Results and discussion
30 min, packaged in plastic bags and stored at 5 C until analyzed.
A central composite design was used with moisture content Considerable interest has been paid in fortifying cereals
(11.0–15.0%, wet base), screw speed (220–340 rpm) and feed rate with high-protein, high-lysine material to increase the
(22.0–26.0 kg/h, wet base) being independent process variables.
Response surface methodology was applied to the experimental
protein content and improve the essential amino acid
data using a commercial statistical package, Design-Expert version balance of extruded products [5, 6]. The high lysine
6.01 (Statease, Minneapolis, USA). A polynomial equation was content (1.4 g/100 g) makes chickpeas a good enhancer
fitted to the data to obtain a regression equation. The statistical of protein quality when combined with cereal grain
significance of the terms in the regression equation was examined proteins, which are low in lysine but rich in sulfur amino
by ANOVA. Response surface plots were generated with the same
software. acids [3]. Also, there is a growing interest in increasing
the dietary fiber content of foods including extruded
Bulk density. The bulk density was calculated by measuring the snacks from a health standpoint [7]. Oat flour was chosen
actual dimensions of the extrudates. The diameter of the extrudates for its relatively high dietary flour to be included in the
was measured with a vernier caliper and the lengths per unit weight
(grams) of samples were determined. The bulk densities of the formulation of snack food produced in this study [8].
extrudates were determined using the equation: Similarly, carrot powder and ground hazelnut were used
as sources of carotenoids and vitamin E, respectively.
Qd ¼ 4=pd 2 l ð1Þ
Physical properties and expansion characteristics of
where Qd= bulk density (grams/centimeter3), d= diameter of the extruded snack products has an important role in the
extrudate (centimeters), and l= length per gram of the extrudate acceptability of the final product. Most snack products are
(centimeters/gram).
expected to have a puffed structure, which can be
Solid density. The volume of the extrudates was determined using measured and quantified, by a number of methods such
ground extrudates (particle size: 100–200 mm) in a graduated glass as expansion, density and porosity. In this study bulk
cylinder after tapping ten times by hand. The apparent solid density, expansion (radial, axial, overall) and porosity of
densities of the extruded samples were then calculated as mass per
unit volume (grams/centimeter3). an extruded snack food enriched with chickpeas, oat flour,
carrot and hazelnut were analyzed using response surface
methodology. The regression equations describing the

Table 2 Regression equation Variables BD (R2=0.95) OE (R2=0.89) RE (R2=0.95) AE (R2=0.89) P (R2=0.94)


coefficients for bulk density
(BD, g/cm3), overall expansion Constant +0.22 +3.37 +2.83 +1.19 +6.30
(OE), radial expansion (RE), X1 0.07a +0.58a +0.22a +0.14a +1.55a
axial expansion (AE), and po- X2 +0.03a 0.13b +0.13a 0.10a +0.53a
rosity (P) of extruded snack X3 +2.8103b +0.03b 4.3103b +5.7103b 0.07b
product in terms of coded vari- X12 +0.04a 0.26a 0.08a 0.08a 0.24b
ables. The R2 values in paren- X22 +0.02a 0.37a 0.15a 0.07a 0.63a
thesis show the correlation co- X32 2.5103b +0.12b +0.05a +0.02b +0.19b
efficients. NS Not significant at X1X2 0.02(NS) +0.11b +0.11a 4.2103b +0.63a
95% confidence interval, X1 X1X3 3.0103b 0.02b +0.02b 4.5103b +0.21b
screw speed (rpm), X2 feed X2X3 +0.02a 0.17b 0.06b 0.03(NS) 0.26b
moisture (%), X3 feed rate
a
(kg/h) Significantat 95% confidence interval
b
Not significant at 95%confidence interval
476

Fig. 2a, b Effect of extrusion variables on overall expansion. a


Feed moisture versus screw speed at 24 kg/h feed rate. b Feed rate
versus feed moisture at 280 rpm screw speed

effect of extrusion variables on measured parameters of


extruded snack in terms of coded variables is given in
Table 2. The coefficients in the regression equation can be
used to examine the significance of each term relative to
each other [9]. The ANOVA of the terms in each equation
was also included in Table 2. Moisture content of the
extrudates ranged from 4.4 to 10.5% (dry basis) after
extrusion.

Fig. 1a–c Effect of extrusion variables on bulk density. a Feed


moisture versus screw speed at 24 kg/h feed rate. b Feed rate versus
screw speed at 13.0% feed moisture. c Feed rate versus feed
moisture at 280 rpm screw speed
477

Bulk density

Bulk density of extruded samples was measured using the


dimensions of the product. It has been stated that this
method is easier and less time-consuming than the glass
bead displacement method that has been used for irregular
extrudate surfaces [10]. The surfaces of the products in
this study were relatively smooth and uniform. Statistical
analysis showed that feed rate had no effect on the bulk
density of extruded product at the 95% confidence level,
whereas bulk density changed quadratically with screw
speed and feed moisture (Table 2). An interaction was
also found between feed moisture and feed rate (Table 2).
Bulk density decreased with decreasing feed moisture and
increasing screw speed (Fig. 1a). Although bulk density
did not change with feed rate at constant feed moisture
(Fig. 1b), the interaction of feed rate with feed moisture at
a constant screw speed is apparent in Fig. 1c. Bulk density
stayed fairly constant at low feed moisture values and
increased as the feed rate increased at high moisture
contents (Fig. 1c).

Expansion properties

Although extrudate expansion properties are generally


expressed in radial expansion in most studies, the samples
in our study were tested for their radial and axial
expansions since expansion can occur in both lateral
and longitudinal directions during extrusion [11]. Table 2
shows that while screw speed and feed moisture had a
significant effect on radial and axial expansion, the effect
of feed rate was not found to be significant on the three
expansion properties at 95% confidence interval. The
effect of feed rate and feed moisture on overall expansion
were also found to be insignificant (Table 2). There was
only one two-way interaction, which was obtained for
radial expansion for screw speed-feed moisture (Table 2).
Overall expansion increased with increasing screw
speed and remained constant with feed moisture and feed
rate (Fig. 2a, b). Radial expansion increased with in-
creasing screw speed steadily (Fig. 3a, b) and tended to
increase with feed moisture especially at higher screw
speeds (Fig. 3a). Radial expansion also increased with
feed moisture, as indicated in Fig. 3c. Axial expansion
increased with increasing screw speed and, in contrast to
radial expansion, decreased as feed moisture increased
(Fig. 4a, b). These results demonstrate that screw speed is
a powerful variable for changing the expansion properties
of the product. As the screw speed is increased the shear
applied by the reverse pitch elements to the material
inside extruder barrel would increase giving rise to a more
developed and uniform dough with better expansion
properties at the die exit.

Fig. 3a–c Effect of extrusion variables on radial expansion. a Feed


moisture versus screw speed at 24 kg/h. b Screw speed versus feed
rate at 13% moisture. c Feed rate versus feed moisture at 280 rpm
screw speed
478

Fig. 4 Effect of extrusion variables on axial expansion. a Screw


speed versus feed rate at 13% moisture. b Feed moisture versus
screw speed at 24 kg/h feed rate

Porosity

Air pockets or gas cells are created during extrusion


giving expanded products with lower bulk densities.
Porosity created by this mechanism may be used to
measure the extent of expansion in the extruded products.
The results show that screw speed and feed moisture had
a significant effect on the porosity of the samples and
that there existed an interaction between these two
variables within the limits of this study (Table 2). Porosity
increased with increasing screw speed and also with feed

Fig. 5 Effect of extrusion variables on porosity. a Feed moisture


versus screw speed at 24 kg/h feed rate. b Feed rate versus screw
speed at 13% feed moisture. c Feed rate versus feed moisture at
280 rpm screw speed
479

moisture especially at higher screw speeds (Fig. 5a, b). Acknowledgements The authors would like to thank DEFRA and
An increase was observed in porosity with increasing feed the partners of the LINK Eating, Food and Health Programme (EFH
11) in their support of this research.
moisture possibly due to the presence of more water
available for creating nucleation sites (Fig. 5c).
In conclusion, screw speed has the most pronounced
effect on the physical and expansion properties of a References
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