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DOI:https://doi.org/10.31838/ijpr/2020.12.03.136
Research Article
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.
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S. Deepak et al / Optimization of Variables that Influence Puffing Quality of Hot Air Oven Puffed
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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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S. Deepak et al / Optimization of Variables that Influence Puffing Quality of Hot Air Oven Puffed
Quinoa
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S. Deepak et al / Optimization of Variables that Influence Puffing Quality of Hot Air Oven Puffed
Quinoa
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
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S. Deepak et al / Optimization of Variables that Influence Puffing Quality of Hot Air Oven Puffed
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
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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S. Deepak et al / Optimization of Variables that Influence Puffing Quality of Hot Air Oven Puffed
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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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S. Deepak et al / Optimization of Variables that Influence Puffing Quality of Hot Air Oven Puffed
Quinoa
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