Extrusion cooking of barley flour and process parameter optimization by using response surface methodology

Abstract BACKGROUND: The nutritional profile of barley places it in a prime position for development of a new extruded–expanded snack food with health benefits. It was therefore the aim to investigate the effect of extrusion processing variables on system parameters (specific mechanical energy, die pressure and die melt temperature) and physical properties (expansion, bulk density, texture and color) of barley flour extrudates and to optimize processing conditions for production of extruded snack food from barley flour by response surface methodology. RESULTS: Barley flour with 219.7 g kg −1 moisture content was extruded at different die temperatures (140–160 °C) and screw speeds (150–200 rpm) through a co‐rotating twin‐screw extruder. The system parameters as well as product responses were mainly dependent on temperature, whereas the screw speed imparted a lesser effect. Extrudates produced under extrusion conditions of 160 °C, 150 and 200 rpm and at 164 °C and 150 rpm had higher preference levels of appearance, taste, texture and overall acceptability than that of other selected extrudates for sensory analysis. The optimal conditions for minimum bulk density and desired textural characteristics and color of extrudates correspond to a temperature of 156 °C and screw speed of 166 rpm. CONCLUSION: The results suggested that use of barley flour in extruded snack products offers a desirable variation in diet and can take advantage of the nutritional quality of barley. Copyright © 2008 Society of Chemical Industry