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ISSN 0975-2366

DOI:https://doi.org/10.31838/ijpr/2020.12.03.136
Research Article

Optimization of Variables that Influence Puffing Quality


of Hot Air Oven Puffed Quinoa
S. DEEPAK1*, T. SHARMILA2, M. MAHESWARI3, M.S. SHIVASWAMY4
1*
Department of Food Technology, Kongu Engineering College, Erode, India.
2-4
Department of Food Technology, Kongu Engineering College, Erode, India.
Email ID: deepaksiragiri@gmail.com
Received: 20.01.20, Revised: 23.02.20, Accepted: 25.03.20

ABSTRACT
Quinoa is a nutritious and bioactive pseudocereal which can be transformed into a crispy and expanded ready-
to- eat snack by hot air oven puffing. Puffing study was conducted by subjecting the moisture-conditioned (0.2-
1.8 ml/10g sample) and salt-pretreated (0-1%) quinoa grains to high temperature (240-280 ºC) for short time
(20-60 s). The Puffing yield, expansion ratio, flake size and overall acceptability of puffed quinoa increased while
bulk density decreased with decrease in moisture level and salt concentration and increase in oven
temperature and residence time. Optimum condition for puffing was 0.2ml moisture/10g sample, 0% salt
concentration, 253.8ºC oven temperature and 60 seconds residence time. As fourfold volume expansion
achieved from optimized condition, manufacturers can be profited.
Keywords: Expansion, Ready-to-eat, Puffing Yield, Sensory.

INTRODUCTION level for infants, children and adults [1]. It


Quinoa is an emerging food crop originated in remains as a good source for thiamine,
Andean region of South America and has been riboflavin, niacin, pyridoxine, folate, vitamin C
introduced into many tropical and temperate and vitamin E [8]. Besides providing essential
countries for exploring its value [1]. It is called as nutrients, it also delivers additional health benefits
mother grain because of its unique nutritional due to bioactive peptides, squalene,
properties and its ability to grow under extreme phytoecdysteroids, polypenols, flavonoids, β-
stress conditions [2]. As it is resistant to draught, carotene, tocopherols, phytosterols, fagopyritols
frost, pests, salinity, nutrient deficiency and other and glycine betaine having antioxidant,
adverse abiotic and biotic factors, its productivity antihypertensive, anticarcinogenic,
rate is increasing year by year [3], [4]. In terms of hypocholesterolemic and hypoglycemic
quantitative and qualitative nutrition, quinoa is properties [12], [9]. The nutritional and health
considered as one of the best source for protein potential of quinoa drives demand for coming up
[5]. It has protein content of 16.3g per 100g with diverse range of functional food products
drymatter, which is greater than in rice (8.8g), with special emphasis on snack food segment
barley (11g), corn (10.5g), wheat (14.8g), rye [13]. Puffing is a simple low cost technology used
(11.6g) and Sorghum (12.4g) [6]. Unlike cereals, for producing aerated, porous, crispy, light and
quinoa is a rich source of lysine and other cellular structured expanded ready- to-eat
essential amino acids required by body [7]. The products having superior palatability profile [14].
protein efficiency ratio (2.99) and biological value Currently, puffed products such as puffed rice,
(87.73%) of quinoa protein is equivalent to that of popcorn, popped wheat etc have wide popularity
milk protein casein [8]. Though quinoa has and consumed by mass population for its
relatively higher fat content of 5.2- 9.7%, it affordability and sensory quality [15], [16]. The
majorly constitutes unsaturated essential fatty mechanism of puffing involves exposure of grains
acids such as linoleic acid (48.2-56%), oleic acid to high temperature for short residence time so
(24.5-26.7%) and linolenic acid (3.8-8.3%) [9]. that sufficient pressure builds up within the shell
The absence of gluten and prolamin residues of grain which at one point burst to release the
makes it a gluten free food suited for celiac rapidly expanding starchy endosperm [17]. The
disease [10]. It can be preferred by people inherent phenotypic factors of grain influencing
suffering from diabetes because of its low puffing quality are endosperm type, amylose and
carbohydrate level and glycemic index [11]. amylopectin ratio, husk interlocking, bran content
Minerals such as calcium, phosphorous, and its thickness, pore size, grain size and shape,
potassium, magnesium, iron, manganese, density etc [18], [19]. Puffing can be done using
copper, zinc and sodium in quinoa can contribute heating mediums such as sand, hot air and oil
greater percentage to recommended daily intake [20]. Sand puffing, a widely used traditional

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S. Deepak et al / Optimization of Variables that Influence Puffing Quality of Hot Air Oven Puffed
Quinoa

method consumes more energy and cause value of data was used for analysis of variance.
environmental pollution [21]. Moreover, the The independent variables coded as A, B, C and
presence of sand residues pose health issues [22]. D were moisture level (0.2-1.8 ml/10g sample),
Oil popped product has short shelf life period salt concentration (0-1%), oven temperature
due to rancidity on storage [23]. Being (240-280 ºC) and residence time (20-60 s)
contamination free and involves no usage of oil, respectively. The dependant variables measured
hot air puffing is a preferred method for from analysis were puffing yield (%), expansion
producing puffed product [24]. Moreover, the ratio, flake size (mm3), bulk density (g/ml) and
process can be made energy efficient by heat overall acceptability. The model and its
extraction from spent hot air or by recirculation terminologies were considered significant only if it
system [25]. As the manufacturers buy the grains had less than 5% level of significance (p<0.05).
from weight basis and sell the expanded product Apart from that, a validation trial was conducted
in consumer market by volume basis, the degree at optimized condition and analyzed using
of expansion and yield obtained on puffing has Minitab 19 statistical software.
direct effect on profit on sales [26]. Consumer
would get satisfied if the puffed product has good C. Puffing Quality Measures
sensory quality [27]. The objective of current study Puffing yield (%) was calculated by measuring the
is to optimize the processing conditions of hot air percentage of grains fully puffed out of the total
oven puffing that influence puffing quality of grain mixture in terms of weight [28]. Expansion
nutritionally rich quinoa using response surface ratio states the degree of expansion upon puffing.
methodology. It was estimated by the ratio of volume of puffed
grains to volume of raw grains [24]. Flake size or
METHODOLOGY puff size (mm3) was determined by the ratio of
A. Process Description volume of puffed grains to number of puffed
The white variety of quinoa grain was purchased grains [29]. Bulk density (g/ml) was measured by
from Organic India Private Limited. Sample size tapping method. It is the ratio of mass of puffed
of about 10g was used in each experimental trial. grains to volume of puffed grains [30]. Sensory
The grains were moisture conditioned and salt- analysis was conducted based on 9 point hedonic
pretreated by spraying salt solution. After scale. The organolepic quality of coded and
tempering for 30 minutes at 27ºC, the grains randomly arranged puffed product was evaluated
were spread evenly as a thin layer in a tray and by 3 trained persons and 7 untrained persons
loaded into hot air oven cabinet maintained at based on parameters like color, texture, taste,
certain fixed temperature and treated for fixed odour, flavor and overall acceptability [23].
exposure time. Fully puffed grains were then
separated from the unpuffed grains by RESULTS AND DISCUSSION
handpicking and packed in low density D. Puffing Yield
polyethylene pouches. Puffing yield of hot air oven puffed quinoa
obtained from different trials varied from 0.67%
B. Design of Experiment and Statistical Analysis to 61.41% (Table I). The model has F value of
Design Expert (StatEase) software package was 19.83 and is highly significant (p<0.0001) (Table
used for designing the experiment, analysis and II). Lack of fit is not significant which implies that
optimization. Box Behnken Design having 4 the model is compatible to data. The second
independent variables each having 3 levels and 5 order polynomial equation (1) fitted for puffing
dependant variables were chosen for study. The yield in coded form after eliminating non
trials were replicated three times and its average significant terms is,

Table 1: Independent Factors of Experiment and its Corresponding Values of Dependant Variables
Trial Independent Dependant Variables
Variables
A B C D Puffing Expansion Flake Bulk Overall
Yield (%) Ratio Size Density Acceptability
(mm3) (g/ml)
1 1 1 280 40 34.61 3.03 8 0.4 7.14
2 1.8 0.5 260 20 14.87 2 4 0.5 5.42
3 1 0 240 40 16.31 2.65 6 0.41 5.57
4 1 0 280 40 54.02 3.11 9 0.35 7.29
5 0.2 0.5 280 40 61.41 3.35 12 0.32 7.57

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Quinoa

6 1 0.5 280 20 41.38 2.85 8 0.43 7.57


7 1.8 0.5 240 40 2.93 0.9 3 0.58 4
8 1 0.5 280 60 35.33 2.9 8 0.39 5
9 1 0.5 240 20 0.67 0.13 3 0.5 4.29
10 0.2 0.5 260 20 35.16 2.7 9 0.38 7.71
11 1 0.5 260 40 27.22 2.76 6 0.44 7.14
12 1 0.5 260 40 21.7 3.08 7 0.36 7.2
13 1.8 0.5 260 60 28.65 2.51 5 0.46 6
14 1 1 240 40 5.74 1.57 5 0.48 4.86
15 0.2 0.5 260 60 61.25 3.3 11 0.37 8.29
16 0.2 0.5 240 40 20.71 2.76 7 0.39 6.29
17 1.8 1 260 40 22.5 2.2 3 0.48 5.71
18 1 0 260 60 37.28 3.17 9 0.39 7.43
19 1 0.5 260 40 30.98 3.32 6 0.46 6.5
20 1.8 0 260 40 25 2.47 5 0.46 6.42
21 1 1 260 20 23.66 2.59 6 0.43 6.57
22 0.2 0 260 40 49.72 3.78 14 0.32 8.57
23 1 0 260 20 25 2.61 7 0.4 6.71
24 1.8 0.5 280 40 30.97 2.78 5 0.42 6.86
25 1 0.5 260 40 20.44 2.27 7 0.44 7.14
26 1 0.5 240 60 24.04 2.7 7 0.46 6
27 1 0.5 260 40 20.86 2.76 6 0.42 7.28
28 0.2 1 260 40 41.49 3.14 9 0.41 8.29
29 1 1 260 60 31.53 2.68 8 0.42 7
A-Moisture (ml/10g sample), B-Salt Concentration (%)
C-Oven Temperature (ºC), D-Residence Time (s)

Table 2: Analysis of Variance and Fit Statistics for Different Models


Source F Value
Puffing Yield Expansion Flake Size Bulk Density Overall
(%) Ratio (mm3) (g/ml) Acceptability
Model 19.83S 9.16S 41.66S 0.0181S 16.80S
A-Moisture Level 79.36S 29.62S 115.69S 0.0420S 83.69S
B-Salt 8.65S 5.18S 10.23S 0.0070S 3.23
Concentration
C-Oven 132.77S 41.57S 30.51S 0.0217S 59.97S
Temperature
D-Residence Time 22.63S 14.93S 10.23S 0.0019 1.16
AB 0.3727 0.3195 - - 0.3064
AC 1.82 3.88 - - 4.14
AD 1.72 0.0189 - - 0
BC 0.8870 2.33 - - 0.5196
BD 0.2208 0.5156 - - 0.1393
CD 9.82S 14.82S - - 30.35S
A 2
14.58 S
0.0074 - - 0.3632
B2 3.74 0.9871 - - 0.9122
C 2
0.4835 9.99S - - 42.50S
D 2
1.92 3.20 - - 3.88
Lack of Fit 1.02 0.5587 3.74 0.3559 1.74
R2 0.9520 0.9016 0.8741 0.8152 0.9438
Adj R2 0.9040 0.8032 0.8531 0.7844 0.8876
Pred R2 0.7801 0.6055 0.8106 0.7433 0.7203
Std. Dev 4.69 0.3273 0.9930 0.0262 0.3884
C.V % 16.10 12.48 14.19 6.19 5.87
S
- Significant terminologies (p<0.05)

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Puffing Yield (%)  24.24 - 12.07  A - 3.98  B  15.61  (Table I). As model is significant (p<0.0001) and
2 lack of fit is not significant, the model can be
C  6.45  D - 7.35 - CD  7.04  A
used for predicting the response (Table II). The
(1) regression equation (2) stating the effect of
The higher F value (132.77) of oven temperature independent variables on expansion ratio without
(C) reveals its prominence effect on puffing yield insignificant terms is,
followed by moisture level (A) and residence time Expansion Ratio  2.84  0.514  A  0.215  B  0.61
(D) (Table II). The variation in salt concentration C  0.365  D - 0.63  CD - 0.41  C 2
(B) has least effect on puffing yield. From Fig. 1, ( 2)
increase in puffing yield with increase in oven On comparing the F values (Table II), expansion
temperature and residence time may be due to ratio of puffed quinoa is highly influenced by
increased steam pressure development causing oven temperature (C) followed by moisture level
puffing of more grains [31], [32]. Swarnakar et (A), residence time (D) and salt concentration (B).
al., 2014 stated that popping percentage When oven temperature and residence time
increase upon increment in residence time by increase (Fig. 3), expansion ratio increases due to
more heat exposure [22]. The added moisture increase in rate of generation of steam under this
level and salt concentration decreases yield (Fig. condition and by which pressure differential
2) as the melting point of pericarp decreases and between grain and surrounding is high enough to
starch structure collapse upon heating [33]. favor sudden greater expansion [14]. The
Moreover, salt bounds water and elevates boiling negativity of interaction term CD and quadratic
point leading to reduction in yield [34]. Mishra et term C2 means that at a very high temperature
al., 2015 found a significant reduction in puffing (280 ºC) and too long residence time (60 s),
yield at high level of moisture and salt expansion ratio decreases due to carbonization
concentration [35]. [36]. Similar results have been stated by
Chinnaswamy & Battacharya (1983) in which
higher expansion ratio of puffed rice was
obtained at temperature between 240 ºC to 270
ºC, while further increment in temperature
resulted in charring of rice [37]. In case of
increment in moisture level and salt concentration
(Fig. 4), negative effect was observed in
expansion ratio and it might be due to softening
of grain pericarp reducing its pressure holding
capacity [23]. Ertas et al., 2009 found the sharp
reduction in expansion volume of popcorn at very
Fig. 1: Effect of Oven Temperature (C) and
high moisture level of 14% [38].
Residence Time (D) on Puffing Yield

Fig. 3: Effect of Oven Temperature (C) and


Fig. 2: Effect of Moisture Level (A) and Salt
Residence Time (D) on Expansion Ratio
Concentration (B) on Puffing Yield
E. Expansion Ratio
Expansion ratio should be high enough for a
puffed product to derive profit. Expansion ratio of
puffed quinoa ranges between 0.13 to 3.78

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Quinoa

Fig. 4: Effect of Moisture Level (A) and Salt Fig. 6: Effect of Moisture Level (A) and Salt
Concentration (B) on Expansion Ratio Concentration (B) on Flake Size

F. Flake Size G. Bulk Density


Flake size of puffed quinoa is within 3 to 14 mm3 As the bulk density is the ratio of mass to volume,
(Table I). Linear model was suggested and it was the highly expanded structure should have lower
found to be significant (p<0.0001) as inferred bulk density. Bulk density of puffed quinoa
from model F value of 41.66. Lack of fit is not obtained from different treatments varied from
significant for the model (Table II). The linear 0.32 to 0.58 g/ml (Table I). The suggested linear
equation expressing the effect of significant model is significant (p<0.0001) and lack of fit is
process parameters on flake size of puffed quinoa not significant (Table II). The model reflecting the
is given as, effect of puffing conditions on bulk density of
Flake Size (mm3 )  7  3.08  A  0.916  B  1.58  C puffed quinoa after neglecting the non significant
 0.916  D (3) terminologies is expressed as,
Bulk Density (g/ml)  0.423  0.059  A  0.024  B  0.042
F value of moisture level (A) is 41.66 and it is the  C - 0.012  D (4)
most effective process parameter affecting flake It can be observed from Table II that moisture
size of puffed quinoa followed by oven level (A) having high F value of 61.27 exhibit
temperature (C) (Table II). Salt concentration (B) majority contribution to bulk density, whereas
and residence time (D) have least effect on flake residence time (D) is the least affecting
size. Similar to the effect of process variables on parameter. The greater the oven temperature and
expansion ratio, flake size of puffed quinoa too residence time, lower is the bulk density (Fig. 7). It
increased with increase in oven temperature and is because of greater degree of expansion,
residence time (Fig. 5) and decrease in moisture transforming hard raw grain into an aerated and
level and salt concentration (Fig. 6). Ertas et al, light weighed puffed quinoa [30]. Similar results
2009 reported that flake size of popcorn cultivars have been obtained by Nath & Chattopadhyay,
such as Ant Cin-98 and Con cin-98 are higher at 2007 in which bulk density of puffed potato snack
optimum moisture content of 12% than at 14% decreased with increase in puffing temperature
[38]. Quinn et al., 2005 stated that flake size of and puffing time [20]. On increase in moisture
popcorn can be increased by increasing pressure level and salt concentration (Fig. 8), bulk density
gradient between grain and atmosphere [29]. As value increased to greater extent which is not
heating at high oven temperature and residence desirable [39]. Prinyawiwatkul et al., 1995
time increases pressure gradient between grain described the positive correlation of moisture level
and surrounding, flake size of puffed quinoa also and bulk density of extrusion puffed snack [40].
increases [17], [35].

Fig. 5: Effect of Oven Temperature (C) and Fig.7: Effect of Oven Temperature (C) and
Residence Time (D) on Flake Size Residence Time (D) on Bulk Density

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Fig. 9: Effect of Oven Temperature (C) and


Fig. 8: Effect of Moisture Level (A) and Salt
Residence Time (D) on Overall Acceptability
Concentration (B) on Bulk Density

H. Overall Acceptability
On sensory evaluation, the mean value of overall
acceptability for different trials varied from 4 to
8.57 (Table I). The quadratic model represented
below having F value of 16.8 is significant
(p<0.0001) and lack of fit is not significant (Table
II). It can be used for navigating the design space.
The model was reduced by neglecting the non
significant terms and given below,
Overall Acceptability  7.05  1.03  A  0.868  C  1.07 
CD - 0.994  C 2 (5)
Overall acceptability of puffed quinoa is greatly
affected by linear term moisture level (A) (F value Fig.10: Effect of Moisture Level (A) and Salt
= 83.69) followed by oven temperature (C) (F Concentration (B) on Overall Acceptability
value = 59.97). It is not significantly influenced
by salt concentration (B) and residence time (D) I. Optimization and Validation
(Table II). The negative relationship of moisture Optimization was done with aim to obtain desired
with overall acceptability (Fig. 9) is because of responses such as lower bulk density and higher
high hardness and incomplete expansion resulted puffing yield, flake size, expansion ratio and
which is not liked by panelist [35]. Kantrong et overall acceptability. The Optimum solution
al., 2018 reported the increment in hardness and having maximum desirability of 0.962 was
decrement in crispiness of extrusion puffed snack selected. It was predicted to get puffing yield of
with increase in moisture level [41]. If oven 61.16%, expansion ratio of 4.20, flake size of
temperature increases (Fig. 10), overall 11.43 mm3, bulk density of 0.34 g/ml and
acceptability of puffed quinoa also increases but overall acceptability of 8.44 at optimum level of
too high temperature cause charring of grains 0.2 ml moisture/10g sample, 0% salt
leading to darker unattractive color and burnt concentration, 253.8 ºC oven temperature and
flavor on consumption [42], [32]. Similar results 60 s residence time. In order to validate the
have been obtained by Joshi, 2011 in which model, a verification trial with three replications
overall acceptability of puffed rice increased with using optimized solution was performed and
increase in oven preheating temperature but its analyzed for its variance. The puffing yield of
negative quadratic term infers the reduction in 61.76%, expansion ratio of 4.1, flake size of
acceptability if exposed to elevated temperature 10.73 mm3, bulk density of 0.37 g/ml and
zone for long time [43]. overall acceptability of 8.53 obtained. The actual
and predicted response were in close range
without significant difference (p<0.05).

CONCLUSION
The nutritious and bioactive ready-to-eat puffed
quinoa produced by hot air oven puffing method

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Quinoa

can be used to alleviate nutrition deficiency in 11. E. Gordillo-Bastidas, D. A. Díaz-Rizzolo, E.


society. It was found in study that all dependant Roura, T. Massanés and R. Gomis, “Quinoa
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