Influence of process parameters and added starches on resistant starch content and sensory properties of maize extrudates

Maize grits with or without starchy additives (native wheat starch, distarch phosphates, soluble fiber) were extruded through a single‐screw laboratory extruder Brabender KE 19/25 with a controlled barrel temperature in three zones and in a head, die diameter 4 mm, comprising a compression ratio of the screw of 2:1. The purpose was to influence resistant starch (RS) content together with improving/saving key physicochemical properties by controlling extrusion cooking variables (water addition into feed of 5–20%, screw speed 80–120 rpm, temperature, mass fraction of the additive in the dry premix 0–50%). The influences of most starchy additives were negligible. Pre‐gelatinized cross‐linked starch and soluble fiber nutriose influenced significantly the process pressure, where a low value exhibited high values RS. Based on the data of 48 trials, 7 mathematical optimization models were computed. High RS content worsened the expansion ratio. To obtain a RS content of 1%, it was necessary to decrease expansion ratio to 1.7 where the breaking strength was acceptable. The result of minimizing resistant starch content created an expansion ratio from 2.6 to 2.7, a breaking strength ≤1 N/mm2 and a RS content (maximum) of 0.2%.