SHELF LIFE ANALYSIS OF TORTILLA MADE WITH NIXTAMALIZED LAGKITAN

CORN FLOUR
CHAPTER I
INTRODUCTION

1.1 BACKGROUND OF THE STUDY

Shelf Life Quality
Gould mentioned in his works that there is a need to have a good understanding of

preservation techniques in conferring microbiological safety food stability. Thus further

understanding can only be obtained in knowing its properties.

According to Gould (1996), a good understanding of the preservation techniques can

confer microbiological safety and stability to food can aid the selection of the most

appropriate method for shelf extension

Rheological Properties

On Barnes’ book of An Introduction to Rheology, rheology deals with establishing the

pre-assumptions of mechanical behavior based on the micro to nanostructure of the

material and its measurements are essential tools for characterizing component

materials and finished products, and monitoring process conditions, as well as

predicting product performance and consumer acceptance. He also defined it as the

academic study of food structure that is conducted in isolation from the wider

commercial and consumer context.

With this, it was mentioned by Kato (2000) that the rheological properties of food

provides a fundamental aspect in terms of knowing the structure like that of the

functionality of food is improved significantly with a novel processing technology like

high pressure (HP), which can partially reduce allergenic proteins in rice (Kato et al.

2000).

Water Activity
Rapid deterioration of food can be due to biological and chemical changes brought by

high water content and any drying process will concentrate these solutions. If it is

increasing concentration, rather than decreasing water content per se, that preserves

food, other methods of increasing the concentration of a food's aqueous phase should

also enhance its stability. (Troller, 1978)

Nixtamalization
The process of cooking maize kernels in alkali and steeping in cooking water with

series of washing, at least twice, to ensure that there are no more remaining organic

components and excess alkali in the maize kernels is called nixtamalization. (Arendt &

Zannini, 2013). The product obtained after the process is called nixtamal which is then

ground to produce a soft dough called masa, used for producing tortillas and other

maize-based food products.

Statement of the problem:

Iron-deficiency anemia (IDA) has been a serious nutrition problem in the

Philippines, which affects both the health and economic sectors of the country.

According to the latest Expanded National Nutrition Survey (2018), there has been a

decrease in the prevalence of IDA in adults from 9.0 to 8.3%, although wealth quintile

still includes the rich, it is still most prevalent to the poorest.

Homemade nixtamalized maize flour or made using a small-scale processor is

usually ready-to-eat products which has typically short shelf life compared to
industrially-produced nixtamalized maize flour due to the advanced technology used to

make it. Although having a short shelf life, this will benefit those target population, which

are usually from poor countries, they can utilize the abundance of maize and its price

being low-cost. (Gwirtz & Garcia-Casal, 2013)

1.2 Scope and Limitations:

The study focuses on the analysis of the shelf life of nixtamalized corn flour and

how to improve its shelf life. Its physicochemical and rheological properties will be

assessed to examine the quality of the tortilla that will be made using the nixtamalized

corn flour. This study will only cover a single type of corn, Lagkitan corn, which will be

provided for and by the researchers, and only one kind of product will be used to assess

its acceptability. The study will be done through lab experimentations and food

evaluations to a number of people.

1.3 Significance of the Study:

This research would be beneficial to people who have micronutrient deficiencies

that can be addressed by the nixtamalization of corn flour and have alternative to rice

since the production of rice in the Philippines is declining. In this study, we can propose

alternatives to rice due to its inaccessibility, especially to the poor, because of the

government addresses the issue with more rice imports which takes a toll on the

agricultural economy of the Philippines, increasing its lost by 29% (Caro, 2018). With

the food evaluation, the researchers can come up with recipes that will suit the

preferences of the majority of respondents that can be marketable to the public if

accepted.
1.4 Objectives:
Generally, the objective of the study is to analyze the shelf life of the produced

nixtamalized corn flour and produce a product using the nixtamalized corn flour.

The specific objectives of the study are:

1. To conduct recipe standardization of tortillas by using nixtamalized corn flour and

non-nixtamalized corn flour;

2. To characterize the sensory attributes of the tortilla based on its texture, color,

appearance, taste, and general acceptability;

3. To evaluate the acceptability of the product through food evaluation, and;

4. To compare the shelf life of the tortillas made from nixtamalized corn flour to the

tortillas made from non-nixtamalized corn flour

 CHAPTER II
REVIEW OF RELATED LITERATURE

2.1 Corn as Substitute for Rice Consumption

2.2 Corn Flour and Tortilla Delicacies

2.3 Corn Structure and Composition

After wheat and rice, corn is the third important food grain. A corn kernel is

composed of four parts: endosperm (82-83%), pericarp (5-6%, germ (10-11%), and tip

cap (0.8-1.0%) See figure 1.

Figure 1. Parts of a Corn Kernel

The endosperm is the corn’s energy storage meaning this part of the kernel contains a

large number of cells; each consists of starch granules positioned in a continuous matrix
of protein. The cell walls consist of proteins, phenolic acids and non-starchy

polysaccharides (β-glucan and arabinoxylan). Corn has two types of endosperm - floury

and horny. Floury endosperm contains loosely packed starch granules surrounding the

central fissure, while horny endosperm has tightly packed, smaller starch granules

toward the periphery. The pericarp is the outermost covering of the kernel,

characterized by its high crude fiber content consisted of hemicelluloses, cellulose, and

lignin. The pericarp’s thickness varies depending on the corn type (Singh, 2013). The

germ contains the genetic information, enzymes, vitamins and minerals, which helps the

corn grow to a fully bloomed plant.  The tip tap connects the kernel to the cob, water

and nutrients flow through the tip, and is not covered by the pericarp. (PSCEM, n.d.)

Different types of corn have different characteristics compared to one another.

For example, waxy corn is a corn variety with grains that when cute, has a waxy

appearance and has only branched-chain starch. The starch from waxy corn is

generally 99% amylopectin compared to regular corn, which contains 72-76%

amylopectin and 24-28% amylose. Amylopectin is a branched form of starch of high

molecular weight, while amylose is a smaller unbranched or linear form of starch. Dent

corn or also called “field” corn is the major crop used to make food, animal feed,

industrial products; the only variety to be considered for cornstarch manufacturing. The

sweet or green corn is considered a specific mutation of dent corn that has kernels

containing a high percentage of sugar in the milk stage. (Themson, n.d.)

2.4 White Corn and its Nutritional Composition

White corn (Zea mays L. var. indentata) is a variety of sweet corn that is native to

Mesoamerica, most likely in Mexican Highlands. In the Philippines, 20% of the Filipino

population considers corn as staple food predominantly in the regions of Visayas and

Mindanao. In times of hardships, white rice is used as a substitute for rice while the

yellow corn is used as feeds for livestock. Visayan White corn is a healthier staple than

rice due to its low glycemic index (GI) resulting to gradual release of glucose into the

bloodstreams, lessening the risks of diabetes. An increase in white corn consumption is

believed to help reduce the dependence of the Philippines on rice imports.

In terms of macro- and micronutrients, white corn contains higher amounts than

boiled white rice. White corn has 12g water, 357 kcal, 8g protein, and 1.5 grams of fat.

White corn also has higher crude and dietary fiber content having 1.4g crude fiber and

4.5g dietary fiber (Philippine FCT, 1997). White corn can be advantageous for diabetic

patients because of its low GI. 

2.5 Lagkitan Corn

Los Baños Lagkitan (Zea mays) or also know as Philippine Glutinous Composite

#2 contains the mutant waxy gene (WX), which gives the corn’s glutinous texture and

white kernels. Lagkitan corn is composed of crosses among natie glutinous varieties,

Mexican flint corn varieties and downy nmildew resistant varities from Los Baños. With

these characteristics from different varieties, recurrent selection was used to obtain

substantial yield, increased mildew resistance, improved plant type and excellent eating
quality. The yield of Lagkitan corn ranges from 6.5 to 8.5 tons per hectare and can be

harvested after 70 to 75 days after planting (Logrono et al, 2003)

2.6 Shelf Life Studies

 CHAPTER III
METHODOLOGY

3.1 Time and Place of Study

The study will be conducted from March 2020 to April 2020 at the Bio-Assay

Laboratory of the Institute of Human Nutrition and Food, College of Human Ecology,

University of the Philippines – Los Baños.

3.2 Materials

Dried IPB Var. 6 or Lagkitan Corn will be purchased from the Institute of Plant

Breeding while the other ingredients needed in making tortillas will be obtained and

bought from the local market of Los Baños and commercially-available tortillas in nearby

supermarkets. The equipment that will be needed for cooking the tortilla will be

requested from the institute.

3.3 Nixtamalization

The type of nixtamalization process that will be adapted is the ecological

nixtamalization process according to Figueroa et al. (2006). 1 kilogram of Lagkitan corn

will be cooked for 30 minutes with 2 L of water and 1% (w/w) of calcium carbonate

[Ca(OH)2]. Once cooked, the grains are to be steeped for 16 hours at room

temperature. The pericarp-free water will be separated from the grain, and the liquid left,

called nejayote, will be collected. After steeping and separating the liquid from the

grains, the grains will be brought to the Institute of Plant Breeding for milling to turn the

corn kernels into grits. The figure below shows the step-by-step process to be done
using the process of the ecological nixtamalization to the milling of corn kernels into

corn grits.

2 liters 1 kilogram 20 g Calcium

Distilled Water Lagkitan Corn Carbonate

Figure 1. Diagram of Ecological Nixtamalization Process (Cordero, 2019)

3.4 Preparation of Corn Flour Tortillas

The recipe to be used in making both the nixtamalized and non-nixtamalized corn

flour tortillas for the study will be adapted from Isabel, the creator of the website Isabel

Eats. The list of ingredient from the original recipe used in making corn tortillas is listed

on Table 1.

Table 1. Treatment and Preparation for Corn Tortilla

Ingredient Tortilla
Masa Harina (c) 3.75
Salt (g) 3.3
Hot Water (ml) 360
Olive Oil (ml) 5

1. Add 2 cups masa harina and 2/3 teaspoon salt in a large bowl. Mix together with a
spoon.
2. Pour 1 1/2 cups hot water and 1 teaspoon olive oil into the bowl and mix together
until all the water is absorbed. Using your hands, form the dough into a big ball. The
dough should be firm and springy when touched, not dry or super sticky. If the mixture is
too dry, add more water in small amounts until the dough is springy and holds together.
3. Place the dough ball in the bowl and cover it with a clean kitchen towel or plastic
wrap. Let the dough rest for 20 minutes. This will help ensure that all the water gets
absorbed.
4. Divide the dough into 12 equal pieces. Roll each piece into a ball with the palms of
your hands and place them in the mixing bowl. Cover the bowl with a clean kitchen
towel or plastic wrap to keep the balls moist while you're working.
5. Preheat a griddle or large nonstick skillet over medium-high heat.
6. Open the gallon-sized Ziploc bag and cut the seams on each side so that it makes
one large rectangular piece of plastic. Open the tortilla press and lay the plastic inside of
it so that it covers the upper and bottom parts of the tortilla press.
7. Place one dough ball in the middle of the tortilla press, close the top and gently press
to flatten it out. Open the tortilla press and peel back the Ziploc bag to transfer the
tortilla to your hand.
8. Place the flattened tortilla onto the hot skillet and cook for 20 seconds. Flip it over and
cook for 20 more seconds to seal in the heat. Flip it over again and cook for about 40
seconds or so, until the tortilla starts to bubble or puff up and beautiful brown marks
form. Flip over one last time and cook until beautiful brown marks form.
3.5 Sensory Evaluation

In evaluating both of the products to be used in the study which are the

nixtamalized corn flour tortilla and the commercially available corn tortilla in

supermarkets, thirty BS Nutrition students from the University of the Philippines – Los

Baños are to be selected to evaluate the products through convenience sampling. BS

Nutrition students are the selected since they have the knowledge on food evaluation.

The respondents will be accommodated properly, to be located in a well-lighted and

ventilated room, where they can evaluate both samples. Since there are two samples,

respondents will be provided soda crackers to cleanse their palates. Finally, while

consuming and evaluating the samples, the respondents will be given a 7-point hedonic

scale to evaluate each tortilla sample in terms of it color, taste, texture, aftertaste, and

overall acceptability.

3.6 Budgetary Requirements

Printing
Question Php 50.00
Consent Forms 50.00
Hedonic Scale 120.00
Research 200.00
_____________________
SUBTOTAL PHP 420.00

Materials

Dried Lagkitan Corn Php 60.00

 Salt 20.00
Water 50.00
Olive Oil 156.00
Gas 100.00
_____________________

PHP 386.00

3.7 Shelf life test

3.7.1 Shelf Life Test of Tortilla Made With Nixtamalized Corn Flour

The shelf life of tortilla made using nixtamalized corn flour will be determined by

three setups wherein temperature and the number of days exposed are the factors to be

considered that affects shelf life, all while the tortillas are placed in a microwaveable

plastic container. The researcher will be using the accelerated shelf life method where

the typical shelf life test, which extends to a long duration, shortens by deliberately

increasing the rate of deterioration by temperature increase (Shena,n.d.). Typical

temperature for accelerated shelf life tests ranges from 35 – 40 degrees Celsius (°C)

(Science Direct, n.d.) Table 1 will be used to determine the exact day and in what

temperature will the tortilla deteriorate. After determining the day on which the tortillas

deteriorate, an equation will be used to determine how long would the

Table 1. Sampling Plan for Accelerated Shelf Life Test for Tortilla Made With
Nixtamalized Corn Flour (Haouet et al, 2019)
Day 1 1 1 1 1
  s 1 2 3 4 5 6 7 8 9 0 1 2 3 4
Temperature (°C)                              
35                              
38                              
40                              
 3.7.2 Shelf Life Test of Tortilla Made With Non-nixtamalized Corn Flour

The shelf life of tortilla made using nixtamalized corn flour will be determined by

three setups wherein temperature and the number of days exposed are the factors to be

considered that affects shelf life, all while the tortillas are placed in a microwaveable

plastic container. The researcher will be using the accelerated shelf life method where

the typical shelf life test, which extends to a long duration, shortens by deliberately

increasing the rate of deterioration by temperature increase (Shena,n.d.). Typical

temperature for accelerated shelf life tests ranges from 35 – 40 degrees Celsius (°C)

(Science Direct, n.d.) Table 2 will be used to determine the exact day and in what

temperature will the tortilla deteriorate:

Table 2. Sampling Plan for Accelerated Shelf Life Test for Tortilla Made With Non-
nixtamalized Corn Flour (Haouet et al, 2019)
Day 1 1 1 1 1
  s 1 2 3 4 5 6 7 8 9 0 1 2 3 4
Temperature (°C)                              
35                              
38                              
40                              

3.8 Microanalysis

According to the Philippine National Standard along with the Food and Drugs

Administration, tortillas, which fall under ethnic flour-based confectioneries

classification, will observe the standard set for processed foods under the food

description Breakfast Cereals and Snack Foods. Table 3 shows the microorganisms to
 be tested and standard limit of the population of the microorganisms based on the

PNS/FDA 32:2011.

Table 3. Microbiological limits of ethnic flour-based confectioneries

Test Microorganism n c m M
Yeast and Molds, cfu/g 5 2 10 10
Coliforms, MPN/g 5 2 10 10
n – numbers of samples tested
c – maximum number of samples > m but not more than M
m – guide level
M- maximum acceptance level

3.9 Food Evaluation

References:

Atienza, L. M. (2019). Proximate Properties, Functional Components, and Vitamin and

Mineral Content of Nixtamalized Lagkitan Corn (Zea mays L.). EC Nutrition, 14,
360-372.
Moreno, R. M. M., Figueroa, J. D. C., Santiago-Ramos, D., Villa, G. A., Sandoval, S. J.,
Rayas-Duarte, P., ... & Flores, H. E. M. (2015). The effect of different
nixtamalisation processes on some physicochemical properties, nutritional
composition and glycemic index. Journal of Cereal Science, 65, 140-146.
Morales JC, Zepeda RAG (2017) Effect of Different Corn Processing Techniques in the
Nutritional Composition of Nixtamalized Corn Tortillas. J Nutr Food Sci 7: 580.
doi:10.4172/2155-9600.1000580
Food and Nutrition Research Institute. (1997). The Philippine food composition tables
1997. Manila: Department of Science and Technology, Food and Nutrition Research
Institute.
Singh, Narpinder & Kaur, Amritpal & Shevkani, Khetan. (2013). Maize: Grain
Structure, Composition, Milling, and Starch Characteristics. Maize: Nutrition
Dynamics and Novel Uses. 65-76. 10.1007/978-81-322-1623-0_5.
7.3a Composition of Corn and Yield of Ethanol from Corn. (n.d.). Retrieved from
https://www.e-education.psu.edu/egee439/node/672
A.b., Salazar, Josue, & Los Banos, College. (1970, January 1). Description of corn
cultivar: "Los Banos Lagkitan"- Philippine glutinous composite 2 and improved
"Macapuno". Retrieved from https://agris.fao.org/agris-search/search.do?
recordID=PH2003001531
Arámbula-Villa, G., González-Hernández, J., & Ordorica-Falomir, C. A. (2002, May 25).
Physicochemical, Structural and Textural Properties of Tortillas from Extruded
Instant Corn Flour Supplemented with Various Types of Corn Lipids. Retrieved from
https://www.sciencedirect.com/science/article/abs/pii/S0733521001903728?
via=ihub
Liu, Jie, Yuan, Wang, Ruijuan, Liu, … Guihong. (2019, June 6). The Properties and
Tortilla Making of Corn Flour from Enzymatic Wet-Milling. Retrieved from
https://www.mdpi.com/1420-3049/24/11/2137#cite
Los Baños Lagkitan Corn - Our Technologies. (n.d.). Retrieved from
https://ovcre.uplb.edu.ph/research/our-technologies/article/192-los-banos-lagkitan-
corn
Maya‐Cortés, D. C., Cárdenas, J. de D. F., Cuevas‐Villanueva, R. A., Cortés‐Martínez,
R., Véles‐Medina, J. J., & Martínez‐Flores, H. E. (2009, December 11). Whole‐grain
corn tortilla prepared using an ecological nixtamalisation process and its impact on
the nutritional value. Retrieved from
https://ifst.onlinelibrary.wiley.com/doi/abs/10.1111/j.1365-2621.2009.02095.x
MPRO_admin. (2018, February 2). Promoting rice and white corn combination as a
staple for Filipinos. Retrieved from https://www.up.edu.ph/promoting-rice-and-white-
corn-combination-as-a-staple-for-filipinos/
Thomsen, L. (n.d.). Maize - Corn. Retrieved from
http://www.starch.dk/isi/starch/maize.asp
Haouet, M. N., Tommasino, M., Mercuri, M. L., Benedetti, F., Bella, S. D., Framboas,
M., … Altissimi, M. S. (2019, February 11). Experimental accelerated shelf life
determination of a ready-to-eat processed food. Retrieved from
https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6379691/
Accelerated Shelf Life. (n.d.). Retrieved from
https://www.sciencedirect.com/topics/food-science/accelerated-shelf-life