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International Journal of Agricultural

Science and Research (IJASR)


ISSN(P): 2250-0057; ISSN(E): 2321-0087
Vol. 6, Issue 5, Oct 2016, 353-362
TJPRC Pvt. Ltd

EFFECT OF PROCESS PARAMETERS ON THE PROXIMATE COMPOSITION


AND SENSORY PROPERTIES OF CORN EXTRUDATES
SHRUTHI. V. H1, SHARANAGOUDA HIREGOUDAR2 , UDAYKUMAR NIDONI3,
RAMACHANDRA. C T4 & KISAN JHADAV5
1

Research Scholar, Department of Processing and Food Engineering, College of


Agricultural Engineering, University of Agricultural Sciences, Raichur, India

2,4

Assistant Professor, Department of Processing and Food Engineering, College of


Agricultural Engineering, University of Agricultural Sciences, Raichur, India

Head, Department of Processing and Food Engineering, College of Agricultural


Engineering, University of Agricultural Sciences, Raichur, India
5

Assistant Professor, Department of Biotechnology, College of Agriculture,


University of Agricultural Sciences, Raichur, India

ABSTRACT

twin screw extruder at different levels of temperature (110, 120 and 130 C), feed moisture (15, 17.5 and 20 %) and feed
composition (92:4:4, 94:3:3 and 96:2:2) at constant screw speed (350 rpm). The extruded product was evaluated for
proximate composition and sensory parameters. Sensory evaluation was conducted on a nine point hedonic scale method.
A Box-Behnken experimental design and response surface methodology was used to evaluate the significance of
independent and interaction effects of extrusion process variables. The independent variables had significant (p 0.05)

Original Article

The study focussed on the use of corn (variety: Hema: NAH-1137) along with pigeonpea and rice bran
(both at 2 to 4 %) for production of nutri-rich ready-to-eat extruded snack product. The process was carried out using

effects on proximate composition of extrudates. The optimized condition was found to be 127.66 C temperature, 18.96 %
feed moisture and 92:4:4 feed composition at constant screw speed of 350 rpm. The sensory results indicated that
extrudates prepared were mostly accepted by panel. The products developed with optimized parameters contained 12.26 %
protein, 66.01 % carbohydrates, 1.28 % fat, 10.58 % crude fiber and 2.34 % ash content with a desirability of 0.746.
KEYWORDS: Extrusion, Temperature, Feed Moisture, Feed Composition, Proximate Composition & Sensory Evaluation

Received: Sep 21, 2016; Accepted: Oct 07, 2016; Published: Oct 14, 2016; Paper Id.: IJASROCT201643

INTRODUCTION
Extrusion is an important and popular food processing technique classified as a high temperature short
time process to produce fiber rich products (Vasanthan et al., 2002). Harper (1979) was the first to study extrusion
processing of food material (Mercier et al., 1989). Extrusion is an energy efficient continuous process, which
combines a number of unit operations i.e., mixing, cooking, shearing, puffing, final shaping and drying
(Harper, 1979). In the extruder, food is mixed mechanically, cooked to high temperature, pressure and is subjected
to shear generated in the screw-barrel assembly. The cooked melt is then texturised and shaped in the die
(Arhaliass et al., 2003). Extrusion technology is very useful from the standpoint of nutritional value as nutrient
losses are lower compared to other thermal processing methods (Moscicki et al., 2003). It offers several advantages

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354

Shruthi. V. H, Sharanagouda Hiregoudar, Udaykumar Nidoni, Ramachandra. C T & Kisan Jhadav

over other cooking processes, such as faster processing time and significant reduction in energy consumed, which results in
lower product price. It is becoming more and more popular in the production of snack foods due to their technological
advantages over traditional food processing techniques (White, 1994).
Corn has become an attractive ingredient in the extrusion industry due to its attractive yellow colour and great
expansion characteristic, which is one of the important parameters in the production of a cereal-based extruded snack food
in terms of the functional properties of the final product (Tahnoven et al., 1998). Rice bran can also be used in extrusion
cooking to produce nutritional extruded product (Liu et al., 2011). Due to the high antioxidant activity and abundance in
raw materials, polysaccharides extracted from rice bran can be developed as a new dietary supplement and functional food
to replace some rare medicinal plants (Zha et al., 2009). Pigeonpea brokens are also acceptable for incorporation in
extruded product (Sobota and Rzedzicki, 2009). Therefore, the objectives of this study was to determine the possibility of
application of agro-waste products such as pigeonpea brokens and rice bran for the production of snack food products and
to evaluate the proximate composition and sensory properties of the corn extrudates.

MATERIAL AND METHODS


Preparation of Composite Flour
The raw material such as corn (variety: Hema (NAH-1137)) and pigeonpea brokens (variety: TS3R) were
procured from Seed Unit, University of Agricultural Sciences, Raichur and rice bran of fresh unparboiled sona masoori
(variety: BPT 5204) from M/S. Laxmi Venkateshwara Industry, Raichur (Karnataka). All raw materials were cleaned and
ground separately in grinder and passed through 0.88 mm sieve as recommended by twin screw extruder manufacturer.
The composite flour were prepared by mixing corn, pigeonpea brokens and rice bran (Table 1) with calculated
amount of water and the flour was allowed to equilibrate for 15 min. The blended samples were conditioned to achieve
required moisture content by spraying with water and mixed uniformly. The samples were kept in buckets and stored at
4C for 12 h (Deshpande and Poshadri 2011). The feed material was allowed to stay for 3 h to equilibrate at room
temperature prior to extrusion. This pre-conditioning procedure was employed to ensure uniform mixing and proper
hydration and to minimize variability in the state of feed material. The proximate composition of raw materials is given in
table 2.
Table 1: Proportion of Composite Flour (%)
Sl. No.
1
2
3

Raw Material
Corn, %
Pigeonpea brokens, %
Rice bran, %

A
92.00
4.00
4.00

B
94.00
3.00
3.00

C
96.00
2.00
2.00

Table 2: Proximate Composition of Raw Materials


Feed Composition
Corn (Hema: NAH-1137)
Pigeonpea brokens (TS3R)
Rice bran (BPT 5204)

Protein
(%)
13.40
18.12
14.40

CHO
(%)
75.49
59.68
37.96

Crude
Fiber (%)
2.36
6.10
10.55

Fat
(%)
3.92
1.52
17.84

Ash
(%)
2.06
6.52
8.87

Extrusion Process
The experiments were performed using a co-rotating twin-screw extruder (Basic Technology Pvt. Ltd., 3711-12,
Kolkata, India). The ratio of barrel length to diameter ratio (L/D) was 8:1 and 3 mm diameter die was selected. The barrel
Impact Factor (JCC): 4.8136

NAAS Rating: 3.53

Effect of Process Parameters on the Proximate Composition and Sensory Properties of Corn Extrudates

355

zone temperatures were kept constant at 60C throughout the experiments. The speed of cutter was fixed at 150 rpm for all
experiments. Extrudates were cut with a sharp knife, at the exit end of the die and left to cool at room temperature for about
20 min.
Experimental Design
Box-Behnken design of Response surface methodology was employed for optimization of process parameters
(Montgomery

2001).

The

experiments

were

designed

using

Design

Expert

Software,

Version

7.7.0

(State-Ease, Minneapolis, MN). The same software was used for statistical analysis of experimental data. The detail of
experimental design is shown in Table 3.
Proximate Analysis
The proximate composition of the developed corn based extruded product samples were determined using
standard AOAC 2005 methods. The extrudates were analysed for crude protein (Kjeldahl method, AOAC 2005, 960.52A),
crude fat (Soxhlet extraction method, AOAC 2005, 920.85), crude fiber (acid and alkali hydrolysis, AOAC 2005, 920.86),
carbohydrate (AOAC 2005, 996.11) and ash content (muffle furnace method, AOAC 2005, 923.03).
Sensory Evaluation of Extruded Product
Sensory evaluation of the developed nutri-rich extruded product was conducted using a panel of 13 judges.
The members of consumer test panel awarded grades for different quality aspects of nutri-rich, agro-based extruded
product like general colour, flavour, taste, hardness, swallowness, stickiness and overall acceptability (Yagci et al., 2008).
Table 3: Experimental Design as Per Box-Behnken for Coded and Un-Coded Variable Levels
Run

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

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Coded levels
X1

X2

X3

0
0
0
0
0
-1
1
0
0
-1
1
-1
-1
0
0
1
0
1

-1
0
1
0
-1
-1
1
0
0
0
0
1
0
0
1
-1
0
0

1
0
1
0
-1
0
0
0
0
-1
-1
0
1
0
-1
0
0
1

X1
Temperature
(C)
120
120
120
120
120
110
130
120
120
110
130
110
110
120
120
130
120
130

Uncoded levels
X2
X3
Feed Moisture
Feed Composition
(%)
(%)
15.0
96:2:2
17.5
94:3:3
20.0
96:2:2
17.5
94:3:3
15.0
92:4:4
15.0
94:3:3
20.0
94:3:3
17.5
94:3:3
17.5
94:3:3
17.5
92:4:4
17.5
92:4:4
20.0
94:3:3
17.5
96:2:2
17.5
94:3:3
20.0
92:4:4
15.0
94:3:3
17.5
94:3:3
17.5
96:2:2

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Shruthi. V. H, Sharanagouda Hiregoudar, Udaykumar Nidoni, Ramachandra. C T & Kisan Jhadav

RESULT AND DISCUSSIONS


Protein Content (%)
Protein content of corn based extrudates varied from 10.58 to 12.80 per cent. It is observed that the minimum
protein content (10.58 %) was observed for treatment T3M2F3 i.e., 130 C temperature, 17.5 per cent feed moisture and
96:2:2 feed composition whereas, maximum protein content (12.80 %) was observed for treatment T1M1F2 i.e., 110C
temperature, 15 per cent feed moisture and 94:3:3 feed composition as seen from Table 4. The feed moisture had
significant effect on the protein content of the extrudates. As the feed moisture increased the retention of protein content in
the extrudate was increased whereas with the increase in temperature protein content in the extrudate was decreased.
It might be due to denaturation of protein at higher temperature (Figure 1A). Similar results were obtained by Stojceska et
al. (2009) for cauliflower by-products incorporated cereals based ready-to-eat expanded snacks. Increased pigeonpea and
rice bran content in the mixture and decreased corn content results in increased protein content of the extrudate
(Figure 1B). As whole legume flour contains more proteins than cereal starch (Tharanathan and Mahadevamma, 2003),
levels of crude protein increased as a function of increasing rate of pigeonpea and rice bran fortification.
Table 4: Proximate Composition of Corn Based Extruded Product
Protein Carbohydrates Crude Fiber
(%)
(%)
(%)
T2M1F3
12.03
68.01
10.42
T2M2F2
12.14
68.69
10.74
T2M3F3
11.94
67.58
10.29
T2M2F2
12.14
68.71
10.72
T2M1F1
12.31
69.32
11.81
T1M1F2
12.80
69.78
12.28
T3M3F2
11.64
66.48
9.69
T2M2F2
12.14
68.67
10.73
T2M2F2
12.14
68.73
10.75
T1M2F1
12.91
69.37
12.11
T3M2F1
11.81
67.27
9.95
T1M3F2
12.47
69.24
12.16
T1M2F3
12.39
69.97
12.03
T2M2F2
12.14
68.73
10.75
T2M3F1
12.25
68.97
11.67
T3M1F2
10.72
67.14
9.47
T2M2F2
12.14
68.72
10.74
T3M2F3
10.58
66.63
9.58
Average
12.04
68.56
10.90
T: Temperature, C (T1-110 C, T2-120 C, T3-130 C);
Treatments

Fat
(%)
1.27
1.37
1.20
1.36
1.40
1.80
1.13
1.35
1.35
1.92
0.84
1.74
1.69
1.37
1.40
0.94
1.35
1.18
1.37

Ash
(%)
2.24
2.28
2.20
2.29
2.47
2.76
2.09
2.30
2.30
3.03
2.45
2.72
2.61
2.31
2.36
2.01
2.31
2.04
2.38

M: Feed moisture (w.b.), % (M1-15 %, M2-17.5 %, M3-20 %);


F: Feed composition, % (F1-92:4:4, F2-94:3:3, F3-96:2:2)

Impact Factor (JCC): 4.8136

NAAS Rating: 3.53

Effect of Process Parameters on the Proximate Composition and Sensory Properties of Corn Extrudates

357

Figure 1: Response Surface Plot for Protein (%) as a Function of


Temperature, Feed Moisture and Feed Composition
Carbohydrate (%)
Carbohydrate is the important component while assessing the quality and nutritional status of the extruded
product. It is directly related to the acceptability of food product. Carbohydrate content of corn based extrudates varied
from 66.48 to 69.97 per cent. It is observed that the minimum carbohydrate content (66.48 %) was observed for treatment
T3M3F2 i.e., 130 C temperature, 20 per cent feed moisture and 94:3:3 feed composition whereas, maximum carbohydrate
content (69.97 %) was observed for treatment T1M2F3 i.e., 110 C temperature, 17.5 per cent feed moisture and 96:2:2 feed
composition as given in Table 4. The total carbohydrate content of the extruded product increased as there is decrease in
the temperature (Figure 2A). This may be because the higher temperature causes degradation of starch. The feed moisture
also had significant effect on the total carbohydrate content. The total carbohydrate increased as there is decrease in feed
moisture. At higher feed moisture more gelatinization of starch takes place. Similar findings have been reported by Camire
and King (1991) for corn meal based extruded snacks. Increased pigeonpea and rice bran content in the mixture and
decreased corn content results in decreased carbohydrate content of the extrudate (Figure 2B).

Figure 2: Response Surface Plot for Carbohydrate (%) as a Function of


Temperature, Feed Moisture and Feed Composition
Crude Fiber (%)
Extrusion cooking, a process during which a foodstuff, commonly a cereal product, is heated under pressure,
then extruded through fine pores while the super-heated water evaporates rapidly leaving a textured product, can increase
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Shruthi. V. H, Sharanagouda Hiregoudar, Udaykumar Nidoni, Ramachandra. C T & Kisan Jhadav

retention the crude fiber content (Elleuch et al., 2011). It has been observed that crude fiber content of corn based
extrudates varied from 9.47 to 12.28 per cent. The treatment T3M1F2 i.e., 130 C temperature, 15 per cent feed moisture
and 94:3:3 feed composition shows minimum crude fiber content (9.47 %) whereas, the treatment T1M1F2 i.e., 110 C
temperature, 15 per cent feed moisture and 94:3:3 feed composition shows maximum crude fiber content (12.28 %).
The average value of crude fiber content for all treatments was given in Table 4. The feed moisture had significant effect
on the crude fiber content of the extrudates (Figure 3A). As the feed moisture increased, the retention of the crude fiber
content in the extrudate increased. There was significant decrease in crude fiber content of the extrudate upon increase in
temperature. Figure 3B shows the addition of more amounts of pigeonpea brokens and rice bran results in increased crude
fiber content of the corn based extrudate.

Figure 3: Response Surface Plot for Crude Fiber (%) as a Function of


Temperature, Feed Moisture and Feed Composition
Fat (%)
Fat content of corn based extrudates varied from 0.84 to 1.92 per cent. The treatment T1M2F1 i.e., 110C
temperature, 17.5 per cent feed moisture and 92:4:4 feed composition shows maximum fat content (1.92 %) whereas, the
treatment T3M2F1 i.e., 130C temperature, 17.5 per cent feed moisture and 92:4:4 shows minimum fat content (0.84 %).
The average value of fat content for all treatments is given in Table 4. The feed moisture had significant effect on the fat
content of the extrudates (Figure 4A). As the feed moisture increased the retention of the fat content in the extrudate is
increased. Similar results were reported by Vasanthan et al. (2002) for barley flour based expanded snacks. The fat content
in the extrudates decreases as the temperature increases. This is because the burning of fat takes place during the extrusion
process and high temperature burns the fat available in product. Fat content of the corn based extrudate increased with
increase in the amount of pigeonpea and rice bran content in the feed material (Figure 4B).

Impact Factor (JCC): 4.8136

NAAS Rating: 3.53

Effect of Process Parameters on the Proximate Composition and Sensory Properties of Corn Extrudates

359

Figure 4: Response Surface Plot for Fat (%) as a Function of


Temperature, Feed Moisture and Feed Composition
Ash Content (%)
Total ash is sum of all minerals in the product. All natural plant minerals have health promoting effect.
It was observed that the ash content of corn based extruded product varied from 2.01 to 3.03 per cent. The treatment
T3M1F2 i.e.,130 C temperature, 15 per cent feed moisture and 94:3:3 feed composition shows minimum ash content
(2.01 %) whereas, the treatment T1M2F1 i.e., 110 C temperature, 17.5 per cent feed moisture and 92:4:4 feed composition
shows maximum ash content (3.03 %). The average value of ash content for all treatments is given in Table 4. The results
show that ash content of the extrudate decreased as the temperature increased (Figure 5A). The ash content also increases
as the feed moisture increases. The feed composition had significant effect on ash content of the extrudate. As the amount
of pigeonpea and rice bran increased and corn content decreased in the feed composition, the ash content increased
(Figure 5B).

2.790

3.030

2.783

2.395

Ash (%)

Ash (%)

2.593

2.197

2.000

2.535

2.288

2.040

110.00

20.00
115.00
120.00

Temperature (C)

16.25
130.00 15.00

96.00
115.00

Feed moisture (%)

Temperature (C)

17.50
125.00

110.00

18.75

95.00
120.00

94.00
125.00

93.00
130.00 92.00

Feed composition (%)

Figure 5: Response Surface Plot for Ash (%) as a Function of Temperature, Feed Moisture and Feed Composition
Sensory Evaluation
The sensory evaluation of the corn based extruded product revealed that there were significant differences among
the treatments for the organoleptic qualities. The sensory evaluation was carried out on the basis of colour, flavor, taste,
hardness, stickiness, swallowness and overall acceptability of the developed product. The quality was judged by the
consumer panel team consisting of thirteen members. The overall acceptability is varied from 7.36 to 8.43. The average
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Shruthi. V. H, Sharanagouda Hiregoudar, Udaykumar Nidoni, Ramachandra. C T & Kisan Jhadav

scores of extruded product for each characteristic were given in Table 5. The treatment T3M2F1 i.e., 130 C temperature,
17.5 per cent feed moisture and 92:4:4 feed composition mostly accepted by sensory panel (overall acceptability 8.43)
whereas, the treatment T1M1F2 i.e., 110 C temperature, 15 per cent feed moisture and 94:3:3 feed composition was
rejected by sensory panel (overall acceptability 7.36). The second best treatment selected by sensory panel was T3M3F2 i.e.,
130C temperature, 20 per cent feed moisture and 94:3:3 feed compositions with overall acceptability 8.21.
It was observed that, maximum score of colour (8.11), flavor (8.34), taste (8.47), hardness (8.58), stickiness
(8.10), swallowness (8.32) and overall acceptability (8.43) was observed for the treatment T3M2F1. The minimum values of
colour (7.32), flavor (7.46), taste (7.29), hardness (7.13), stickiness (7.06), swallowness (7.11) and overall acceptability
(7.36) was observed for the treatment T1M1F2. Radar graph for overall acceptability of the developed corn based extruded
product is depicted in figure 6.

Figure 6. Radar Graph for Overall Acceptability of the Developed Corn Based Extruded Product
Table 5: Sensory Evaluation of Corn Based Extruded Product
Sensory Attributes
Treatment
T2M1F3
T2M2F2
T2M3F3
T2M2F2
T2M1F1
T1M1F2
T3M3F2
T2M2F2
T2M2F2
T1M2F1
T3M2F1
T1M3F2
T1M2F3
T2M2F2
T2M3F1
T3M1F2
T2M2F2
T3M2F3
Average

Colour

Flavour

7.64
7.34
7.58
7.80
7.75
7.32
7.90
7.71
7.79
6.94
8.11
6.99
7.21
7.66
7.51
7.54
7.79
7.88
7.58

7.54
7.41
7.36
7.58
7.83
7.46
7.20
7.53
7.47
7.13
8.34
7.53
7.13
7.72
7.52
7.77
7.37
7.79
7.54

Impact Factor (JCC): 4.8136

Taste
7.21
7.80
7.78
7.41
7.71
7.29
8.10
7.41
7.58
7.41
8.47
7.48
7.67
7.57
7.23
7.71
7.53
8.08
7.64

Hardness

Swallowness

Stickiness

7.37
7.61
7.82
7.86
6.78
7.13
8.21
7.84
7.69
7.10
8.58
7.47
7.45
7.43
7.38
7.63
7.45
7.96
7.60

7.61
7.53
7.67
7.34
7.24
7.11
7.88
7.35
7.48
6.97
8.32
7.63
7.34
7.82
7.67
7.69
7.33
8.10
7.56

7.81
7.74
7.83
7.48
7.98
7.06
7.93
7.68
7.79
7.01
8.10
7.46
7.25
7.34
7.55
7.53
7.28
7.87
7.59

Overall
Acceptability
7.59
7.62
7.64
7.78
7.83
7.36
8.21
7.65
7.77
7.38
8.43
7.53
7.58
7.82
7.56
7.64
7.62
8.01
7.72
NAAS Rating: 3.53

Effect of Process Parameters on the Proximate Composition and Sensory Properties of Corn Extrudates

S. Em
C.V. (%)
Std. Dev.
p < 0.01
S Significant

0.074
0.042
0.315
S

0.068
0.038
0.289
S

Table 5: Contd.,
0.077
0.099
0.043
0.055
0.328
0.419
S
S

0.080
0.045
0.338
S

0.075
0.042
0.317
S

361

0.063
1.990
0.150
S

T: Temperature, C (T1-110 C, T2 -120 C, T3-130 C);


M: Feed moisture, % (M1-15 %, M2-17.5 %, M3-20 %);
F: Feed composition, % (F1-92:4:4, F2-94:3:3, F3-96:2:2)
Optimization of Extrusion Process Parameters
A numerical multi-response optimization technique was applied (Park et al., 1993) to determine the optimum
combination for the production of extrudate. The assumptions were made to develop a product which would have
maximum score in sensory acceptability so as to get market acceptability.
Under these criteria, the uncoded optimum operating conditions for development of corn based
(Hema: NAH-1137) extrudates were 127.66C of temperature, 18.96 per cent of feed moisture and 92:4:4 feed
composition at constant screw speed of 350 rpm. The responses predicted by the Design-Expert 7.7.0 software for these
optimum process conditions were resulted as follows with desirability 0.746.

CONCLUSIONS
The nutri-rich ready-to-eat extruded snack product was prepared by using corn (variety: Hema: NAH-1137)
pigeonpea brokens and rice bran (both at 2 to 4 %). The extruded product was evaluated for proximate composition and
sensory parameters. The independent variables such as temperature, feed moisture and feed composition had significant
(p 0.05) effects on proximate composition of extrudates. The optimized condition was found to be 127.66 C
temperature, 18.96 % feed moisture and 92:4:4 feed composition at constant screw speed of 350 rpm. The sensory results
indicated that extrudates prepared were mostly accepted by panel. The products developed with optimized parameters
contained 12.26 % protein, 66.01 % carbohydrates, 1.28 % fat, 10.58 % crude fiber and 2.34 % ash content with a
desirability of 0.746. This work has shown the potential of pigeonpea brokens and rice bran in food formulation as well as
in the development of acceptable product from agro-industries by-products.
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Association of Official Analytical Chemists (AOAC), (2005). Official Methods of Analysis of the AOAC International. 18th edn.
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Deshpande, H. W., & Poshadri, A. (2011). Physical and sensory characteristics of extruded snacks prepared from foxtail
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362

Shruthi. V. H, Sharanagouda Hiregoudar, Udaykumar Nidoni, Ramachandra. C T & Kisan Jhadav


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