optimization of formulation for breakfast snacks using adlai (coix lacryma-jobi l.), pineapple...

University of the Philippines Los Baos

COLLEGE OF AGRICULTURE

BACHELOR OF SCIENCE IN FOOD TECHNOLOGY

JAYME PAOLO DUGAY LACISTE Name of Student

OPTIMIZATION OF FORMULATION FOR BREAKFAST CEREAL

SNACK USING ADLAI (Coix lacryma-jobi L.) PINEAPPLE (Anonas comosus L.), AND CARROTS (Daucus carota S.)

Thesis Title

DR. LERJUN M. PEAFLOR Thesis Adviser

___________________

Date of Submission

Permission is given to the following people to access to this thesis:

Available to the general public NO

Available only after consultation with author/thesis adviser YES

Available only those to bound by confidentiality agreement YES

Students Signature: _____________

Signature of thesis adviser: ____________

OPTIMIZATION OF FORMULATION FOR BREAKFAST CEREAL SNACK

USING ADLAI (Coix lacryma-jobi L.), PINEAPPLE (Anonas comosus L.), AND

CARROTS (Daucus carota S.)

JAYME PAOLO DUGAY LACISTE

SUBMITTED TO THE FACULTY OF THE COLLEGE OF AGRICULTURE

UNIVERSITY OF THE PHILIPPINES LOS BANOS IN PARTIAL

FULFILLMENT OF THE REQUIREMENTS FOR

GRADUATION WITH THE DEGREE OF

BACHELOR OF SCIENCE IN FOOD TECHNOLOGY

AUGUST 2015

UPLBCA Form No. 30

Revised 2003

UNIVERSITY OF THE PHILIPPINES LOS BAOS

College, Laguna

UNDERGRADUATE THESIS MANUSCRIPT

FST 200

Name of Student: JAYME PAOLO DUGAY LACISTE

Degree Program: BACHELOR OF SCIENCE IN FOOD TECHNOLOGY

Thesis Title: OPTIMIZATION OF FORMULATION FOR BREAKFAST

CEREAL SNACK USING ADLAI (Coix lacryma-jobi L.)

PINEAPPLE (Anonas comosus L.) AND CARROTS (Daucus

carota S.)

APPROVED DR. LERJUN M. PEAFLOR____ __________________, 2015

Thesis Adviser

APPROVED DR. LOTIS E. MOPERA________ ___________________, 2015

Director, FSC

APPROVED DR. ENRICO P. SUPANGCO____ ___________________, 2015 College Dean

RECORDED DR. MARIA CYNTHIA R. OLIVEROS ________________,2015

College Secretary

iv

BIOGRAPHICAL SKETCH

The author was born on July 23, 1989 in Metro Manila. He is the second child

among three children of Engr. Jaime B. Laciste Jr. and Rosario D. Laciste. He started his

pre-school education in Christ Child School. He obtained his primary education in Saints

Peter and Paul Early Childhood Center. He obtained his secondary education in Santa

Rosa Science and Technology High School. He entered the university 2nd semester of

2006-2007.

The author has an innate liking for mechanical things and has trained in TESDA

for welding and fabrication and automotive troubleshooting.

The author hopes that all of his knowledge obtained from different disciplines of

learning like the technical aspects of vocational courses and the theoretical aspects of a

college education may be used and merge in order to accomplish his tasks in the open

world.

JAYME PAOLO LACISTE

v

ACKNOWLEDGEMENT

The author would like to give thanks to the following for the completion of this

thesis manuscript;

To the Lord Almighty for giving me the fuel to continue despite all the

disappointments, hardships and struggles.

For my family, my mother and my father for providing me financial, emotional

and moral support to finish this course. My sisters Angelica and Regina for supporting

me and being able to help me to finish this thesis. For my Tita Divina Russo for the

financial aid and egging me to dream despite hard times.

For my thesis adviser. Ser Lerjun for pushing me to finish this manuscript and for personally overseeing the development of this manuscript and keeping an eye not

only for the accomplishment of my results but on the technical inputs to make my thesis

much easier.

For the Food Science Cluster Faculty and Staff. Special thanks to mam Ara

Algar for letting me use the equipment for analysis. Tita Dory and Tita Fe for letting me

use the laboratory for analysis. Special thanks to Mang Emong, Mang Buns, Mang Jun

and Kuya Viven for their technical knowledge and expertise in guiding me to use the

different equipment while doing my thesis.

For AMDP for letting me fabricate my tools for the experiment. Special thanks to

Kuya Eugene for being there to fabricate things that I needed in the experiment and

happily doing so.

For Tita Odette, Tita Wena and the staff of the directors office for all the help in formatting this manuscript.

The author would also like to thank the following for a fruitful college life;

Special thanks to Samahang Room 111 and its constituents. Datu, Oliver,

Alexis, Jet, Rudolph, Xavier, Jem, Kennedy Pogi, Jem pwet, Edzel, Marlon etc. The Friendship that was developed inside our home, the New Dorm for keeping me company

in times of need, trials or just simply there because Im bored.

Special thanks to Allan and Kim, Pola, Iane for keeping me company, The former VegaSoc which shared my hobbies, sentiments and my interests.

For my thesis mates and others, Fonzy, Bart, Mikee etc. for keeping me

company in the laboratory to fight the lonesomeness I sometimes feel while doing tests.

And again, for Our Father, God Almighty for everything

vi

TABLE OF CONTENTS

Page

LIBRARY FORM i

UPLB CA Form No. 30 ii

TITLE PAGE iii

BIOGRAPHICAL SKETCH iv

ACKNOWLEDGMENT v

TABLE OF CONTENTS vi

LIST OF TABLES viii

LIST OF FIGURES ix

LIST OF APPENDICES xi

ABSTRACT xii

INTRODUCTION 1

Objectives of the study 3

Scope and limitations of the study. 3

REVIEW OF RELATED LITERATURE 4

Adlai: Biographical description, proximate analysis 4

and cultivation

Nutritional components of pineapple and carrots by-products 6

Micronutrient malnutrition 8

Recommended nutritional intake and

upper level intake of commercial cereals 9

Extrusion 10

Effect of extrusion to different food components 13

Breakfast cereals snacks 17

MATERIALS AND METHODS 20

Materials 20

Methods 20

Preparation of sample powders 20

Preparation of the breakfast cereal snack 20

Preparation of samples 21

Mixing 22

Extrusion 23

Physical attributes 25

Chemical analysis 25

Sensory evaluation 25

Statistical Analysis 26

Experimental analysis 27

Optimization of formulation for breakfast cereal snack 28

Verification 30

vii

RESULTS AND DISCUSSION 31

Moisture content of raw materials 31

Effect of independent variables on the formulation 31

of pineapple-carrot-adlai cereals

Physical Properties 33

Bulk Density 33

Extruded cereal moisture content 35

Water Absorptivity Index 36

Chemical Analysis 38

Breakfast cereal final moisture content 38

Crude fat 40

Ash content 41

Crude protein 43

Carbohydrate content 47

Sensory Evaluation 48

Appearance 48

Flavor 50

Aftertaste 51

Texture 53

General acceptability

Optimization 59

Verification 59

SUMMARY AND CONCLUSION 61

RECOMMENDATIONS 62

REFERENCES 64

APPENDICES 68

viii

LIST OF TABLES

Table Title Page

Number

1 Proximate analysis of polished adlai and adlai flour 5

2 Proximate analysis of pineapple, pineapple (air-oven dried) 7 and carrots

3 Dietary reference intakes (DRIs): Tolerable upper 10

intake levels

4 Nutritional effects of dietary fiber extrusion 15

5 Sales of breakfast cereals by category: volume 18

2007-2012.

6 Design matrix of a full factorial, two factor-three level 28

experimental design

7 Independent variables used in acceptability test 28

8 Moisture content of raw materials 31

9 Effect of independent variables on the physico-chemical 32

composition of the sample.

10 Effect of independent variables on the sensory score 33

11 Predicted and experimental responses at optimum 57

combination

ix

Figure LIST OF FIGURES Page

number

1 Adlai crop 5

2 Varieties of adlai 6

3 Changes in raw materials in an extrusion 11

cooking process

4 Process flowchart for breakfast cereals 21

5 Powdered samples 22

6 Mixed powder 22

7 Piston-type extruder 23

8 Cabinet dryer 24

9 Breakfast cereal snack final product 24

10 Contour plot of bulk density as a function of mixture 34

moisture content against adlai:pineapple-carrots ratio

11 Contour plot of extruded cereal moisture content 36

as a function of mixture moisture content against

adlai:pineapple-carrots ratio

12 Contour plot of water absorptivity index as a 38

function of mixture moisture content against


13 Contour plot of breakfast cereal final moisture content 39

as a function of mixture moisture content against


14 Contour plot of crude fat as a function of 41

mixture moisture content against


15 Contour plot of ash content as a function of 42



16 Contour plot of crude protein as a function of 44

x



17 Contour plot of crude fiber as a function of 46



18 Contour plot of carbohydrate as a function of 48



19 Contour plot of appearance as a function of 49



20 Contour plot of flavor as a function of 51



21 Contour plot of aftertaste as a function of 52



22 Contour plot of texture as a function of 54



23 Contour plot of overall acceptability as a function of 55



xi

LIST OF APPENDICES

Appendices Appendices Page

Table

A Sensory scoresheet for extruded pineapple-carrots 68

adlai cereals

1 Model summary statistics for breakfast cereal final 69

moisture content

2 Sequential model of sum of squares for breakfast 69

cereal final moisture content

3 Model summary statistics for crude fat 69

4 Sequential model of sum of squares for crude fat 70

5 Model summary statistics for ash content 70

6 Sequential model of sum of squares for ash content 70

7 Model summary statistics for crude protein 70

8 Sequential model of sum of squares for crude protein 70

9 Model summary statistics for crude fiber 70

10 Sequential model of sum of squares for crude fiber 71

11 Model summary statistics for carbohydrates 71

12 Sequential model of sum of squares for carbohydrates 71

13 Model summary statistics for appearance 71

14 Sequential model of sum of squares for appearance 71

15 Model summary statistics for flavor 72

16 Sequential model of sum of squares for flavor 72

17 Model summary statistics for aftertaste 72

18 Sequential model of sum of squares for aftertaste 72

19 Model summary statistics for texture 72

xii

20 Sequential model of sum of squares for texture 73

21 Model summary statistics for overall acceptability 73

22 Sequential model of sum of squares for 73

overall acceptability

23 Model summary statistics for bulk density 73

24 Sequential model of sum of squares for bulk density 73

25 Model summary statistics for feed moisture content 74

26 Sequential model of sum of squares for feed 74

moisture content

27 Model summary statistics for water solubility index 74

28 Sequential model of sum of squares for water 74

solubility index

29 Post analysis coefficients table 75


USING ADLAI (Coix lacryma-jobi L.), PINEAPPLE (Anonas comosus L) AND

CARROTS (Daucus carota S.)


ABSTRACT

Adlai or Jobs tears is one of the common crops in Southeast Asia. In the

Philippines, it is considered as an underutilized product. In this study, Adlai powder mixed

with pineapple and carrots powder were used to optimize the formulation of breakfast

cereals snacks. The independent variables are mixture moisture content (35, 40 and 45%)

and adlai:pineapple-carrots ratio (60:40, 70:30 and 80:20). Physical, Chemical, and

Sensory attributes were analyzed in order to optimize the product. A predicted value was

obtained which has ash content of 2.18%, Crude Protein of 7.60%, Carbohydrate content

of 74.10%, bulk density of 0.73 g/ml, extrudate moisture content of 37.13 % and water

absorption index of 2.60 g gel/g solids was attained. The predicted value was compared

with an actual experimental value attained through the same series of test. The results were

reasonably close and therefore the optimum formulation (38.38% mixture moisture content

and 69.40: 30.60 adlai:pineapple-carrots ratio) is suitable for making breakfast cereal

snacks.


USING ADLAI (Coix lacryma jobi L.)1, PINEAPPLE (Ananas comosus L.) AND

CARROTS (Daucus carrota S.)


INTRODUCTION

Adlai or Jobs tears is one of the most common crops in Southeast Asia. Adlai is

historically being utilized as food by peasants. The grain was discovered in the 17th century

by naturalist Georg Eberhard Rumphius which stated that in his day Job's tears were

planted in Java and Celebes on the margins of rice fields. Aldai is closely related to rice

and corn or maize (Zea mays). Both species both belong to the grass tribe Tripsacea. The

grain is known to have higher protein content than most cereals in which adlai can be

utilized to be a good substitute against staples such as corn, rice, wheat and barley.

One of the major concerns of adlai in the Philippines is the underutilization of the

produce. In the Philippines, the grain is largely consumed as an alternative to rice in

Zamboanga del sur. The Department of Agriculture is pushing for the increased

consumption and trade of adlai as an alternative food staple to lessen pressure on rice

production. The Department of Agriculture has announced a central task for the

propagation of the grain.

1 A Food and Science Technology Thesis manuscript submitted in partial fulfillment of the requirements

for graduation with a degree of Bachelor of Science in Food Technology, Food Science Cluster, College of

Agriculture, University of the Philippines Los Baos, prepared under the supervision of Dr. Lerjun M.

Peaflor.

2

In relation to this, the study is aimed to help at least satisfy the requirement to

encourage the increased consumption of the cereal in various product forms.

Among the most nutritive foods is a breakfast cereal snack. A breakfast cereal snack

is an important food especially with the rising demand for a convenient and healthy food.

Lifestyle changes in modern times have changed the trends in foods. In connection with

adlai, most corn and rice based cereal have less of the nutritive value. However, most

Breakfast cereal snacks are fortified to include micronutrients such as minerals and fiber.

One of the ingredients of the experiment is powdered carrots. Carrots is rich in fiber

and is a good source of minerals and vitamins.

Pineapple is also a major fruit produce particularly in Southeast Asia. Among the

largest product from pineapple is pineapple juice. The production of pineapple juice

produces a lot of solid waste by canned industries every year. A good amount of cellulose,

hemicelluloses and other carbohydrates found in the by-products of pineapple juice

processing are lost (Abdullah, 2008).

By combining these three products, there should be a room for improvement and

innovation as these products were never mixed previously into a single snack. Also, the

resulting product should be nutritious similar to the food programs developed by the

Department Of Health in the early 90s. The main purpose of this study is to develop a

formulation of a breakfast cereal snack that is nutritious, cheap and enjoyable to the

younger generation and supplement the nutrients and fiber content of commercial breakfast

cereals snacks.

3

OBJECTIVES

The general objective of the study is to provide a formulation for breakfast cereal

snacks and explore the potential of adlai, pineapple and carrots. Specifically, this study

aims to:

1. Determine the operating parameters that can be controlled and modelled for

formulating a breakfast cereal snack;

2. Determine the optimum combinations of the operating parameters for

formulation of breakfast cereal snack;

3. Establish appropriate formulation for breakfast snack using powdered carrots,

powdered pineapple and adlai powder;

4. To determine the physico-chemical properties of the breakfast cereal snack and;

5. To evaluate the acceptability of the formulated breakfast cereal snack.

SCOPE AND LIMITATIONS OF THE STUDY

The study is only limited to adlai powder extruded with pineapple powder and

carrots powder using a piston-type extruder.

All preparations, processing and experiments were conducted at the Institute of

Food Science and Technology, University of the Philippines Los Baos. Adlai flour was

sieved in the Pilot Plant of the facility. Cooking and preparation was done at the L1 room

and Pilot Plant of the facility. Physico-chemical testing was done at the Food Engineering

Laboratory. Proximate Analysis was done in the Student Labortory and Instrument Room.

The sensory evaluation was done in the University of the Philippines Los Baos campus.

The study was conducted from January 2015 to July 2015.

4

REVIEW OF RELATED LITERATURE

Adlai: Biographical description, proximate analysis and cultivation

Adlai (Coix lacryma-jobi L), is also known as Chinese barley, or Jobs tears (Figure

1). It is an annual crop in a temperate zone but a perennial crop where winter is absent or

mild. The branching of this crop is upright or ascending herb which grows 1-2m tall. The

cordate clasping leaf blades of adlai measures 20-50 cm long, 1-5 cm broad. The grains

are colored white to bluish white, or black, globular orvoid, 6-12 mm long. The crop is a

native to Southeast Asia, but now rather pantropical as cultigen and weed. It is considered

a serious weed in Polynesia, a principle weed in Italy and Korea and a common weed in

parts of South America, China, India, Nepal, and Southeast Asia. The ecological condition

of the Philippines can be contributed to adlais propagation. The optimum range of annual

precipitation is from 6.1 to 42.9 dm, an annual temperature of 9.6 to 27.8 oC and a soil pH

of 4.5 to 8.4. The yield varies as to strains cultivated in different countries. In the

Philippines, yield of unhusked grains is about 3.5 T /ha and loss in hulling is about 30-

40%.

Adlai is generally vulnerable to fungi attack. List of fungi that attacks adlai includes

Cladosporium herbarum, various Fusarium species such as F. equiseti, F. graminearum,

F. monolifrome, F. semitectum, T. taiana, Uredo operta and Ustilago coicis. It is also

vulnerable to Leaf-gall virus and nematode (Meloidogyne incognita acrita). Among others

that attack the plant are rodents and parrots (Duke, 1983). The proximate analysis of adlai

grains and flour is listed in Table 1.

5

Figure 1. Adlai crop (Peaflor, 2013).

Table 1. Proximate analysis of polished adlai grains and adlai flour (Vilbar,

2014).

In the Philippines, adlai is harvested 5-6 months after planting. Most of the process

operation is similar to rice. The grains are dehusked, milled and air dried to 13% moisture

content in a cool and dry place. The adlai is milled through rice and corn mills with up to

6

50% milling recovery depending on varieties. In the Philippines, 4 varieties are commonly

seen (Figure 2).

Figure 2. Varieties of adlai. (A) ginampay, (B) kibua, (C) gulian and (D) tapol

(Vilbar, 2014).

Nutritional components of pineapple and carrot juice

processing by-products

Among the most available by-products available in the canning industry are

pineapple waste pulp and carrot pomace. Pineapple (Ananas comoscus L.) also called as

King of Fruits is one of the most popular non-citrus tropical and subtropical fruit.

Pineapple is processed into various food products such as jam, jelly, beverage and

concentrate. These processes produce large amount of solid wastes such as skin and core.

In perspective, the production of canned pineapple was estimated at about 48 million

standard cases as against 41 million standard case tones in 1996, an increase of almost 16%

7

in the year 2008-2011 (Kothakota, 2013). In the by-products, a good amount of cellulose,

hemicelluloses and carbohydrates are available. These components should increase the

fiber content of a food material once it is added on a product. The chemical composition

of the processed pineapple in Table 2 shows 29.86% crude fiber and 20.4% ascorbic acid

are available which is adequate when incorporated with other foods.

Table 2. Proximate analysis of pineapple, pineapple (air-oven dried) and carrots

powder. (Ackom 2012, and Gazzali, 2014).

Meanwhile, carrot pomace is also an underutilized produce. Carrot (Daucus carota S.) is a

root vegetable, usually orange, purple red, white or yellow in color with a crisp texture

when fresh. The total production of carrot and turnips was estimated as 27.386 million tons

in the world during year 2008. It is a rich source of beta carotene and contains other

vitamins, like thiamine, riboflavin, vitamin B-complex and minerals. Carrot pomace is a

by-product of carrot juice processing. The juice yield in carrots is only 60-70% and even

up to 80%. Carrots has good amount of vitamins, minerals and dietary fiber. However, left-

over pomace produced after juice extraction of carrots does not find proper utilization.

Moreover, carrot pomace is quite perishable as it contains about 88 % of moisture.

However, processing carrot pomace into powder may prolong the shelf life of these

products. Dried carrot pomace has beta-carotene and ascorbic acid in the range of 9.87 to

8

11.57 mg and 13.53 to 22.95 mg per 100 g, respectively (Upadhyay, 2008). A promising

way to utilize the by-products of pineapple and carrot juice processing is to make them in

dried, powdered form and incorporate them into extrudates.

Micronutrient malnutrition

Micronutrient malnutrition is widespread in the industrialized nations. Young

children and women of reproductive age tend to be among those most at risk of developing

the deficiency but can affect all age groups. Worldwide, the three most common forms of

micronutrient malnutrition are iron, vitamin A and iodine deficiency. Throughout the

world, iron deficiency is the most prevalent and an estimate of 2 billion people are affected

at it and 254 million preschool-aged children are vitamin A deficient.

Food fortification. Food fortification refers to the addition of micronutrients to

processed foods. In many situations, this strategy can lead to relatively rapid improvements

at very reasonable costs. In fortifying foods, there must be an adequate amount of

consumption from the target population. Trials conducted in the Philippines revealed that

fortification of monosodium glutamate with vitamin A produces a positive effect on

mortality, improved growth and hemoglobin level in children. Later studies with preschool-

aged children, who consumed 27 g of vitamin A- fortified margarine per day for a period

of 6 months, reported a reduction in the prevalence of low serum retinol concentrations

from 10-26%. Wheat flour fortified with vitamin A and fed as buns to Filipino school

children for 30 weeks had the effect of halving the number that had low liver stores of the

vitamin.

9

Recommended nutritional intake and upper

level intake of commercial cereals

Dietary fiber. Dietary fibers have important physiologic properties. The dietary

reference intakes and dietary guidelines recommend a daily fiber intake of 14 g/1000

calories consumed. Despite the broad range of potential health applications attributed to

dietary fiber, including the treatment of colonic disorders, lower risk of heart disease,

diabetes and colon cancer, the proportions in which they should be fed is not yet optimized.

An increase in fiber in the diet has shown different effects on the body mainly fecal weight

which has increased from 2.8 g to 5.4 g. Another effect of dietary fiber consumption are

increase in H2 production in breath and increase in feeling of bloating and flatulence as an

indication of fermentation activity of bacteria (Vuskan 2008).

Vitamins and minerals. The cereal snack fortified with vitamins and minerals

provide at least 25% of daily requirements for essential vitamins and 17% for iron.

Commercially fortified breakfast cereals is an excellent source of folic acid which

contributes 15% of the daily intake. It also includes vitamin B1 with providing 14% of

overall daily intake. Riboflavin and niacin of breakfast cereals are 15% and 10% of daily

intake respectively and vitamin B6 which is 13% of average daily intake (Gregory, 2004).

Tolerable upper intake levels. Upper Intake Level (UL) is the highest level of daily

nutrient intake that is likely to pose no risk of adverse health effects to almost all individuals

in the general population. Unless otherwise specified, the UL represents total intake from

food, water, and supplements. In the absence of a UL, extra caution may be warranted in

consuming levels above recommended intakes. Members of the general population should

be advised not to routinely exceed the UL. The UL is not meant to apply to individuals

10

who are treated with the nutrient under medical supervision or to individuals with

predisposing conditions that modify their sensitivity to the nutrient.

According to Table 3, the UL of vitamin A and fiber as per se is not defined.

Table 3. Dietary Reference Intakes (DRIs): Tolerable Upper Intake Levels, (Vitamins

Food and Nutrition Board, Institute of Medicine, National Academies) (1998).

Extrusion

Extrusion technologies are efficient manufacturing processes in food industries.

Their main role was developed for conveying and shaping fluid forms of processed raw

materials, such as dough and pastries. Today, their processing factions may include

conveying, mixing shearing separation, heating or cooling, shaping, co extrusion, venting

volatiles and moisture, flavor generation, encapsulation and sterilization.

11

Figure 3. Changes in raw materials in an extrusion cooking process (Guy, 2000).

Principles. The principles of operation in all types of extruders are: raw materials are

fed into the extruder barrel and the screw(s) or piston then convey food along barrels.

Further down the barrel, smaller flights restrict the volume and increase the resistance to

movement of food. As a result, food material fills the barrel and the spaces between screw

flights and becomes compressed resulting into a semi-solid, plasticized mass.

Classification of extruders. Extruders are classified into two types according to

operation: hot and cold extruders.

Based on type of construction extruders are classified into: Single screw and twin

screw extruder

Hot and cold extrusion. Two processes may be done in an extruder. In hot

extrusion, frictional heat and any additional heating that is used cause the temperature to

rise rapidly. The food is then passed to the section of the barrel having smaller flights,

where pressure and shearing is further increased. Food material is then forced through a

die at the end of the barrel as the food emerges under pressure from the die; it expands to

the final shape and cools rapidly as moisture is flashed off as steam.

Cold extrusion otherwise remains at ambient temperature and is used to mix and

shape foods such as pasta and meat products. Low pressure extrusion at temperatures below

100oC is used for products such as, liquorice, fish pastes, surimi and pet foods.

12

Single or double-barrel extruder: Segmented screw/barrel single-screw wet

extruders consists of a live bin, feeding screw, preconditioning cylinder, extruder barrel,

die and knife. Single-screw extruders have relatively poor mixing ability and are usually

supplied with preconditioned material with added steam or water.

Recent years have seen increasing prospects for new products with intricate shapes

and small sizes that are beyond the capabilities of single-screw systems. Twin screw

extruders are developed to fill its inadequacies. The term twin-screw applies to extruder

with two screws of equal length placed inside the same barrel. Twin screw extruders are

more complicated but provide much more flexibility and better control. Twin extruders are

categorized as counter rotating and co rotating twin screw. In the counter rotating position

the extruder screw rotates in the opposite direction while the co rotating acts otherwise.

Co-rotating self-wiping types of extruders are most commonly used in the food industry.

The limitations for single and twin-screw machines are respectively 4% and 20%

fat, 10% and 40% sugar, and 40 and 65% moisture. There is therefore flexibility using

different raw materials when using twin screw against single screw extruders.

Hydraulic-type piston extruder. Most piston extruders are used in foodstuffs in

making pastas and in other industries such as shaping aluminum. These extruders operating

in batch-type extrusions and are advantageous for their economical operation, maximum

product yield and minimal feed accumulation. Another advantage of these extruders are

their high pressure forces which are beneficial for products with very low moisture content.

This type of extruder is typically used for pilot processing and for experimental purposes

due to their ability to produce smaller batches and the easy interchangeability of the die.

The parts of the piston type extruder are; hydraulic piston, base frame and press frame and

the press ram. The hydraulic piston can be water-charged or oil charged. The base frame

13

design relies on the weight and the design of the whole piston assembly. The press ram is

sheathed inside a barrel in which applied force is concentrated inside the barrel thus forcing

the product material into a die.

Physical properties that affect extrusion. The specific gravity is used to calculate

volumetric flow and degree of fill of the screws. The thermal properties are specific heat,

melting point, the enthalpy of fusion and thermal conductivity. Specific heat of foodstuffs

varies from 1500 to 2500 J/kg-K depending on nature and state of material. Additive rule

is used if a material is mixed with different materials. Thermal conductivity lies between

0.1 and 0.5 W/m-K.

Effect of extrusion to different food components

Carbohydrates. Carbohydrates are involved in numerous chemical reactions when

undergoing extrusion. Extrusion cooking is unique due to gelatinization of carbohydrates

occurring in much lower moisture levels (12-22%). Gelatinization may occur but it may

not be complete. The presence of other food compounds such as lipids, sucrose, dietary

fiber and salts affect gelatinization. An increase in temperature, shear and pressure

increases the rate of gelatinization. Starch is predigested when it undergoes extrusion where

amylopectin molecules are easily sheared off in the barrel. In a study, fiber values more

than doubled when 7.5% citric acid was mixed with cornmeal. 30% high-amylose

cornstarch with 5-7.5% citric acid resulted in values of 14% which is 2% more against

100% cornmeal when extruded. The authors of the study speculated that polydextrose may

have been formed inside the extruder. Yield of polymers increased with temperature in

which 93.7% yield was observed at 200oC. (Kumari, 2006).

14

Proteins. Extrusion improves protein digestibility via denaturation which exposes

enzymes-access sites. Denaturation is more pronounced under high shear extrusion

conditions although mass temperature and moisture are also important influences. Since

most extruded products are not high in protein, nutritional evaluation of extruded feeds,

weaning foods and other specialized products have been emphasized. High barrel

temperatures and low moistures promote Maillard reactions. Some studies show that

reducing sugars can also react to lysine thereby lowering protein nutritional value (Kumari,

2006).

Lipids. Foodstuffs that contain less than 10% lipids are extruded because greater

quantities reduce slip within the extruder barrel making extrusion difficult particularly for

expanded products. Lipid oxidation is a major cause of nutritional and sensory qualities in

foods and feeds. However, lipid oxidation does not occur during extrusion due to brief

residence time and occurs more during storage time. Screw wear results in formation of

oxidative rancidity. This is due to the metal shavings from the barrels being incorporated

into the food and acts as a catalyst for oxidation of lipids in foodstuffs.

Dietary fiber. Dietary fiber is the edible part of plants and analogous carbohydrates

that are resistant to digestion and absorption in the human small intestine with complete or

partial fermentation in the large intestine. Dietary fiber includes polysaccharides,

oligosaccharides, lignin, and associated plant substances. Extrusion did not affect uronic

acids (components of pectin) but insoluble non-starch polysaccharides (NSP) increased in

oatmeal and potato peels. Soluble NSP was higher in extruded oatmeals and potato peels,

and corn meal fiber was unaffected by extrusion. Beans which are hard-to-cook, were

extruded under various conditions in order to make them more functional.

Table 4. Nutritional effects of dietary fiber extrusion (Guy, 2000).

15

Total fiber values were unaffected by extrusion but insoluble fiber decreased when

extruded at 25% moisture content. Soluble fibers increased especially in a sample

processed at 30% moisture and 180oC. Increased levels of soluble fiber in citrus peels after

extrusion were correlated with increased in vitro viscosity. However, starch digestion and

diffusion of glucose were not affected by extrusion. Extrusion reduced sugar beet pectin

and hemi-cellulose molecular weight and viscosity. But water solubility increased 16.6%

to 47.5% (Kumari, 2006).

Vitamins. Fortification of extruded foods with micronutrients is popular. The

concern for post process loss of vitamins is aided through spraying of vitamins in the

extruded products. Studies for current vitamins in extruded products focuses more on

stability post process especially folic acid which is typically needed by pregnant women.

Vitamins D and K are fairly stable during food processing, and they are not commonly

used in extruded human foods. In some studies, tocopherols and retinyl palmitate decreased

in puffed snacks containing either fish or partially defatted peanut flour. Rice bran

tocopherol decreased with increasing extrusion temperature, and bran extruded at 120-

140oC lost more tocopherols over a years storage than did bran extruded at 110oC (Shin

et al., 1997). Ascorbic acid is lost in the presence of heat and oxidation. Ascrobic acid

16

decreased in wheat flour when extruded in higher barrel temperatures at low moistures at

around 10%. When ascorbic acid was added to cassava starch to increase starch conversion,

retention of over 50% occurred at levels of 0.4-1.0 % addition. Vitamin A is destroyed by

oxygen and heat. Beta-carotene is added to make foods more orange in color but it is

unstable when heated. Increasing barrel temperatures from 125 200oC resulted in more

than 50% destruction of all trans beta carotene in wheat flour (Kumari, 2006).

Minerals. High fiber foods may abrade the interior of extruder barrel and screws,

resulting in increased mineral content. Previous studies resulted in iron content in extruded

potato flakes increased with barrel temperature. Screw wear iron had high bioavailability

in rats fed with extruded corn and potato. Extrusion and any resulting changes in mineral

content did not reduce utilization of iron and zinc from wheat bran and wheat in adult

human volunteers. Another study shows that extrusion did not compromise the zinc

bioavailability of 85:15 blends of semolina and soy protein concentrate.

Breakfast cereal snacks

Preprocessed cereal-based products, like ready-to-eat cereals to be eaten directly

out of the packaging are relatively new. Since they were first introduced by W.K. Kellog

in the United States, cornflakes have initiated a vigorous development of the breakfast

cereal industry. The world consumption of cereal snacks amount to about 3 million tons.

However, there is an unequal distribution of production throughout the world. The main

cause of this discrepancy is depending upon the population food culture and degree of

development. Breakfast cereal manufacturers aim to supply products for children and pay

attention to taste (sweet flavorings), texture (crispiness), and nutrition (vitamins and

minerals, in particular).

17

Market analysis in the Philippines by Euromonitor was made in 2013 (Table 5).

According to the report, the breakfast cereals market volume sales are set to increase 4%

in 2012 with a compound growth annual interest of 4% from 2012-2017. Convenience is

the key driver of breakfast cereal growth. The childrens breakfast cereals was expected to

see fastest current value growth of 8% in 2012. With more young adults joining workforce

and an increase in the expansion of business process outsourcing in the Philippines,

demand for convenience plays an essential role in changing consumer habits. More adults

continue to consume breakfast cereals in morning as a quick meal. Hot cereals as of the

moment is expected to account for 52% of the breakfast cereals value in 2012. However,

growth of hot cereals has been slower compared to RTE (ready-to-eat) cereals which are

marketed to be fortified with multivitamins and are usually marketed as complete

breakfast meal that would cover all ones nutritional needs. These products tend to target

the middle income segment in the Philippines. The popularity of breakfast cereals stems

from nutritional content mainly energy (350-400 kcal/100 g), nutrients (vitamins, minerals)

and health oriented components (dietary fiber).

Table 5. Sales of Breakfast Cereals by Category: Volume 2007-2012 (Euromonitor, 2013).

Types of

breakfast

cereals

2007 2008 2009 2010 2011 2012

(ton) (ton) (ton) (ton) (ton) (ton)

Hot cereals 9130.00 9449.60 9,733.00 10,054.20 10,406.10 10,780.70

RTE Cereals 3,171.60 3,349.50 3,451.20 3,573.00 3,706.80 3,850.90

-Childrens 2,521.90 2,698.40 2,806.40 2,924.20 3,040.00 3,184.20

-Family 649.70 651.00 644.80 648.80 656.90 666.70

-General 12,301.60 12,799.00 13,184.20 13,627.30 14,133.00 14,631.60

18

Breakfast cereal snacks and extrusion cooking. Over the years, extrusion

cooking has played an important role in developing breakfast products. It is made through

a new cooking concept thermomechanical high temperature short time (HTST) cooking

against the traditional hydrothermal cooking. Currently, there are 2 types of extrusion-

cooked breakfast cereals can be found on the market which are;

Directly expanded extrusion cooking which uses cereals with very low moisture

content (usually 20% below) and relies on highly mechanical cooking. The process relies

more in the mechanical forces which cooks the cereals.

Pellet-to-flakes extrusion cooking which uses cereals on higher moisture in the

range of 22-26% which relies more on thermal components against mechanical forces.

Generally, breakfast cereal extrusion cooking processes involve low moisture

contents (below 25-26%) and high temperatures (above 130-140oC). In such conditions,

starch granules undergo not only gelatinization but also melting due to shear forces. In

extrusion cooking, much parameters of concern as independent variables include screw

speed, moisture content, screw configuration, die temperature etc. while dependent

variables or product outcome parameters include Water Absorption Index, WAI; Water

Solubility Index, WSI; expansion index, bulk density, hardness and sensory characteristics.

(Kothakota, 2013).

Drying and toasting of breakfast cereals. Drying is an essential part of breakfast

cereal processing apart from water removal. It aims to finalize the crispy and crunchy

texture of products by reducing moisture content to the level at which cereal polymers are

in the glassy state. By combining drying with toasting generates blistering and specific

brown color which gives good sensory characteristics. Sensory characteristics such as

19

blistering and a specific brown color gives a bakery taste in breakfast cereal snacks (Guy,

2000).

20

MATERIALS AND METHODS

Materials

Milled Adlai grains was obtained from Southern Tagalog Region Integrated

Agricultural Research Center (STIARC) in Lipa City, Batangas. The carrots was purchased

in a local market in Binan, Laguna and the pineapples was purchased in a local market in

Tagaytay City.

Methods

Preparation of sample powders. Adlai grains was ground using a pin mill. The

powder was passed through mesh 80. The other samples that did not pass through the mesh

had undergone size reduction repeatedly until most of the powder can pass through the

mesh.

The pineapples were washed, peeled, and was processed through a pulper. The pulp

was collected and separated from its juice through the use of a strainer. The pulp was then

dried at 50oC overnight then was grinded to a powder that can pass through a sieve with 80

mesh.

The carrots were washed, peeled and was processed through a pulper. The pulp that

were collected had undergone separation from its juice through the use of a cheesecloth.

The pulp were then dried at 50oC overnight. The resulting product was run through a pin

mill with a mesh 80 sieve. The resulting product was collected as carrot powder.

The adlai, pineapple and carrots powder was subjected to moisture content analysis

using an Ohaus moisture meter.

Preparation of the breakfast cereal snacks. The three components mainly; adlai

powder, dried pineapple powder and dried carrot powder were mixed into different ratios.

21

The prepared mixtures were adjusted with different moisture contents. The samples were

steamed to obtain a semi-gelatinized texture, cooled and was extruded through a piston

extruder with a 13 mm circular diameter die. The samples are then sliced with a blade and

was dried at 50oC overnight. Figure 4 shows the flowchart for making the breakfast cereal

snacks.

Figure 4. Process flowchart for breakfast cereal snacks.

Preparation of samples. Three sample powders were prepared in the study

namely; adlai, pineapple and carrots are shown in figure 5.

Piston

Extrusion

1. Adlai

2. Pineapple

3. Carrots

Mixing

Gelatinization

Water

Cutting Drying

Breakfast

Cereal Snack

22

Figure 5. Powdered samples: (A) Adlai powder; (B) Carrots powder; (C)

Pineapple powder.

Mixing. The three powders were mixed to their respective ratios weight/weight

with a fixed ratio of 50:50 for pineapple and carrots powder. Then, water was added to

adjust the mixture moisture content into three levels. Figure 6 shows the mixed powder.

Figure 6. Mixed powder

23

Extrusion. After achieving a semi-gelatinized mixture, the mixture was extruded

through a piston-type extruder with a die measuring 13mm diameter (Figure 7) and cut into

desired shape.

Figure 7. Piston-type extruder.

Drying. The extruded cereals are dried using a cabinet dryer (Figure 8) for 24 hours

at 50 oC temperature. This was set in order to prevent case hardening of the samples which

might affect different attributes of the product. After drying, the final product was obtained

(Figure 9). The cereals are then subjected into different tests to acquire the following;

24

Figure 8. Cabinet dryer.

Figure 9. Breakfast cereal snack final product

25

Physical attributes

Bulk Density. Bulk density is obtained by using a standard measuring cup where

the cup was filled with the samples until it overflowed. The samples are then scraped and

weighed on a tared measuring cup. The volume of the measuring cup and the weight of the

samples were obtained.

Extruded cereal moisture content. The samples were analyzed before dried. 5

grams of sample was weighed per treatment and were analyzed using an Ohaus moisture

meter.

Water Absorption Index. The Water Absorption Index (WSI) was obtained by

submerging the samples in a beaker for 30 minutes and was centrifuged to 3000 g for 15

minutes. The supernatant was removed. The initial weight of the powdered final product

and the gel produced was recorded.

Chemical analysis

The AOAC method for proximate analysis was followed in order to obtain

numerical values for chemical components such as the final moisture content of breakfast

cereal, crude fat, ash, crude protein, crude fiber and carbohydrate content. The results from

chemical analysis are compared with the values from Composition of foods: Breakfast

cereals: raw, processed, prepared (Douglas, 1982).

Sensory evaluation

Twenty (20) panelists were asked to score samples in terms of appearance, flavor,

aftertaste, texture and general acceptability using a 9-point hedonic scale. Quality scoring

was used in order to numerically categorize the samples. The scores were evaluated using

a scoresheet prepared.

26

Statistical Analysis

In formulating of the adlai :pineapple-carrots breakfast cereal snacks, the

independent variables are coded as X1 (adlai-carrots-pineapple mixture, g/g) and X2

(moisture content of the mixture, %). The dependent variables are coded as Yx. The

responses include; Y1 (extruded cereal moisture content), Y2 (bulk density), Y3 (water

absorption index), Y4 (final breakfast cereal moisture content), Y5 (crude fat), Y6 (ash

content), Y7 (crude protein), Y8 (crude fiber), Y9 (carbohydrate content), Y10 (appearance),

Y11, (flavor), Y12 (aftertaste) and Y13 (texture) and Y14 (general acceptability).

The independent variables were the following: (1) Mixture moisture content, %.

defined as the amount of moisture present in the mixture of adlai, pineapples and carrot

powders. This variable was held at three levels depending on the results of preliminary test

runs; (2) Adlai:pineapple-carrots ratio, g/g. defined as the combination of adlai, pineapple

and carrots that were present in the sample. The ratio between pineapples and carrots were

held at 50:50 while being varied with adlai. This variable was held at three levels

depending on the results of preliminary test runs.

The dependent variables were the following (1) Bulk density, g / ml. the bulk

density is used to check the actual, ungrounded density of the product; (2) Extruded cereal

moisture content, %. the moisture content of the extruded breakfast cereals before drying;

(3) Water solubility index, g gel/ g solids. the water solubility index is the ratio of the

weight of the gel produced when powdered final product was submerged in liquid and the

weight of the powdered final product; (4) Final Breakfast Cereal Moisture Content, Dry

Basis, %. defined as the moisture content of the final product; (5) Crude Fat, %. defined

as the amount of fat that can be extracted in the sample; (6) Ash Content, %. defined as the

amount of incombustible material left after ignition of sample. It is also a rough estimate

27

of mineral content of the samples; (7) Crude Protein, %. defined as the amount of titratable

nitrogen in the sample; (8) Crude Fiber, %. Defined as the amount of indigestible starches

in the sample; (9) Carbohydrates, %. defined as Nitrogen Free Extract. It is the amount of

carbohydrates available in the sample; (10) Appearance. defined as the visual appeal of the

product. Involves the colors, pore development and curvature of samples; (11) Flavor.

defined as the total appeal of the product involving taste and aroma; (12) Aftertaste. defined

as the tartness of the product; (13) Texture. defined as the crunchiness of the sample when

eaten. A balance between cohesiveness and crumbness was explained to be a desirable

measure of the cereals in presence of bite pressure which may be considered as crunchiness;

(14) General acceptability. defined as the overall experience felt by the judge after

ingestion of sample.

Experimental Analysis

In the analysis for optimization of formulation of adlai-pineapple-carrots breakfast

cereal snacks, a full factorial, two-factor, three-level experiment was used to obtain

optimum combinations for the product. The design has produced 9 runs using a face

centered option. Independent variables coded as X has corresponding levels as -1, 0 and

1+ with 0 as center point. Mixture moisture content is coded as X1 and adlai:pineapple-

carrots ratio as X2. Table 6 shows the experimental design using central composite design

that was used in the experiment for formulation of adlai-pineapple-carrots breakfast cereal

snacks. Table 6 also presents the independent variables as they are coded in the

optimization study. Corresponding values of L1, L2 and L3 was based on the results of the

preliminary test runs.

28

Table 6. Design matrix of a full factorial, two-factor, three-level experimental design.

Table 7. Independent variable used in acceptability test.

Optimization of formulation for breakfast cereal snack

Response Surface Methodology (RSM) was used in order to optimize the results

obtained. This was carried out by Design Expert software. Using the optimization function

of the software, an optimum point was established. This optimum point represents the

processing conditions wherein all set physical, chemical and sensory properties overlaps.

Formulating breakfast cereal from adlai, pineapple and carrots using the optimum

combination would deliver product with superior qualities.

Central Composite Design

Run Numbers X1 X2

1 -1 -1

2 1 -1

3 -1 1

4 1 1

5 -1 0

6 1 0

7 0 -1

8 0 1

9 0 0

INDEPENDENT

VARIABLES

SYMBOL

CODED VARIABLE LEVELS

Coded Uncoded -1 0 1

Adlai : Pineapple-

carrot and ratio (kg/kg) X1 PCAR 60:40 70:30 80:20

Moisture content (%) X2 MC 35% 40% 45%

29

In the optimization process, the results from available literatures, preliminary

testing results, and on-point observation served as a basis for setting the acceptable

boundaries or target values of each response in the formulation of breakfast cereal snacks.

The criteria set for acquiring the optimum combination were:

1. Bulk density, the target value was set 0.65 g/ml based on the index by

FAO/INFOODS density database.

2. Extruded cereal moisture content, the target value was set at 40% in order for the

product to gel and aid in the cutting of the extrudate.

3. Water Absorptivity Index, the target value was set at 2.5g gel/g solids in order for

the cereals to absorb more moisture by mixing it to liquid material (i.e milk) without

changing its properties and produce a soggy texture.

4. Breakfast cereal final moisture content, the target value was set at 10% for good

balance between having good sensory characteristics and adequate storage time of

the product.

5. Crude fat, the target value was set at of 2% which is a good fat content value for

consumer preference based on low fat food. It is also advantageous for storage

conditions as it prevents early onset of oxidative rancidity.

6. Ash content, the target value was set at 5% which is identical to commercial

breakfast cereal snacks.

7. Crude protein, the target value was set at 6%. It is identical to commercially

available cereals and lessens the risk of proteolytic degradation during storage

conditions.

8. Crude fiber, the target value was 5% as compared to commercial breakfast cereals.

30

9. Carbohydrate content, the target value was set at 65-70% which is the carbohydrate

content of most cereals snacks and most of the grains.

10. Appearance, the target value was set above 4 based on the scale of commercial

breakfast cereal.

11. Flavor, the target value was set above 4 based on the scale of commercial breakfast

cereal.

12. Aftertaste, the target value was set above 4 in order to quantify the slight tartness

of the cereal as produced from addition of the pineapple powder in the sample.

13. Texture, the target value was set above 4 to score the crunchiness of the sample.

14. General acceptability, the target value was set above 4 as a good measure for the

overall mouthfeel of the sample.

Verification

Verification of the response models was made in order to test the precision of the

generated values against experimental values. The resulting values of the independent

variables that were obtained through Design Expert were used in formulating breakfast

cereals. The breakfast cereals that were made with optimum mixture moisture content and

ratio was subjected to physical, chemical tests and sensory evaluation. The resulting

values obtained from these tests were compared with the predicted data that was generated

and the percent difference was computed.

% = 100/

31

RESULTS AND DISCUSSION

Moisture content of raw materials

The moisture content of the raw materials is very essential to the study. The initial

moisture content of the raw materials were listed in Table 8. Pineapple powder has the

highest moisture content of 15.42 % wet basis while adlai had the least moisture content

at 8.54%. The pineapple had the highest moisture content due to being processed from a

fresh product. This is in contrast with adlai which has a relatively low moisture content

due to the grains being dried prior to storage.

Table 8. Moisture content of the powdered treatments.

Powdered

Treatments

Moisture Content

Wet basis (%) Dry basis (%)

Adlai 8.54 9.33

Pineapple 15.42 18.23

Carrot 9.56 10.57

Effect of Independent variables on the formulation

of the adlai :pineapple-carrots cereal

The effect of independent variables on the optimization of formulation for adlai-

:pineapple-carrots was achieved using Response Surface Methodology. The results from

the experimental data gathered from the formulation of adlai-pineapple-carrots breakfast

cereal snacks are shown in Table 9 and Table 10.

32

Table 9. Effect of independent variables on the physico-chemical composition of the sample.

Legend = Highest Lowest

Sample

Run

Independent Variables Dependent Variables (physicochemical analysis)

Mixture

Moisture

Content adlai:pineapple-

carrots ratio

Bulk

Density

Extruded

Cereal

MC

Water

Absorptivity

Index

Breakfast

Cereal

Final

MC

Crude

Fat

Ash

Content

Crude

Protein

Crude

Fiber

Carbohydrate

content

(%) g/ml (%) g gel/ g

solids (%) (%) (%) (%) (%) (%)

1 30 60:40 0.56 37.13 3.00 8.08 4.07 5.81 10.29 6.04 65.71

2 45 60:40 0.67 35.56 2.40 9.60 1.57 3.65 8.25 2.17 74.76

3 30 80:20 0.79 33.23 2.60 11.68 3.05 2.44 6.93 2.63 73.27

4 45 80:20 0.81 41.76 2.15 13.62 1.29 1.22 4.37 1.67 77.83

5 30 70:30 0.76 35.18 2.65 10.07 3.85 4.97 9.67 4.77 66.67

6 45 70:30 0.78 37.50 2.28 11.36 1.41 2.38 7.07 1.68 76.1

7 35 60:40 0.65 36.35 2.59 9.59 2.89 4.97 7.80 2.52 72.23

8 35 80:20 0.77 38.66 2.40 13.49 2.00 2.91 7.07 2.39 72.14

9 35 70:30 0.79 37.76 2.59 11.23 2.07 2.93 7.46 2.51 73.8

33

Table 10. Effect of independent variables on the sensory scores of the sample

Legend = Highest Lowest

Physical Properties

Bulk Density. Bulk density is a property of powders, granules and other divided

solids. It is the mass of the foodstuffs in a given volume and increases with compaction.

The density also provides a rough estimate of the air spaces developed from processing

foods. Treatment 4 with with 0.81 g/ml which has a combination of 45% mixture moisture

content and 60:40 adlai:pineapple carrots ratio has achieved the highest bulk density of the

treatments. The least dense of all treatments is treatment 1 with 0.56 g/ml which has a 30%

mixture moisture content and 60:40 adlai:pineapple-carrots ratio. The rest of the results are

shown in Table 9. Proper gelatinization and higher expansion is attributed to lower mixture

moisture content. Whereas further increase in bulk density can be attributed to the

reduction in elasticity of dough and lower expansion available for it. However, it is also

noted that increase in bulk density may also be attributed with the water binding capacity

of non-starch polysaccharides (Kothakota, 2013). It must also be noted that an inversely

proportional relationship of bulk density and lateral expansion has been observed with the

Independent Variables Dependent Variables (Quality Scoring)

Sample

Run

Moisture

Content

(%)

Combination Appearance Flavor Aftertaste Texture General

acceptability

1 30 60:40 5.93 3.73 3.67 4.44 5.60

2 45 60:40 6.20 5.53 5.07 3.93 6.27

3 30 80:20 4.80 5.80 6.47 5.13 4.47

4 45 80:20 4.57 4.80 4.73 6.46 3.87

5 30 70:30 5.20 4.60 4.00 4.07 5.73

6 45 70:30 4.80 5.40 5.27 5.27 4.53

7 35 60:40 5.03 5.67 4.73 4.67 4.80

8 35 80:20 4.40 6.07 5.13 5.07 4.47

9 35 70:30 5.10 4.86 4.73 4.73 5.34

34

change in process variables. The bulk density initially increased as the carrot powder was

also increased. However, further addition of fibrous material against carbohydrate content

saw a decrease in bulk density due to the light mass of fibrous carrot powder against other

constituents. Analysis of variance suggests that the adlai:pineapple-carrots ratio is the

significant term (p

35

Figure 10. Contour plot of bulk density as a function of mixture moisture content

and adlai:pineapple carrots ratio.

The high bulk density in junction with a low pineapple-carrots content was achieved due

to the effect of the fibers from carrots and pineapple having less mass against the adlai

powder.

Extruded Cereal Moisture Content. The extruded cereal moisture content is the

actual moisture of the treatments before the products are dried. Previous study by Peaflor

(2013) suggests that a directly proportional relationship was observed between mixture

moisture content and extruded cereal moisture content. The extruded cereal moisture

content is affected by colligative properties of species like carbohydrates, proteins and

other undissolved ingredients in junction with water binding, dissociation of water,

solubility of solutes. These phenomena can be a controlling factor usually from the state of

prevailing conditions (glassy or rubbery state).

The highest extruded cereal moisture is treatment 4 with 41.76% which has a

combination of 45% mixture moisture content and an 80:20 adlai:pineapple-carrots ratio.

The least extruded cereal moisture content is treatment 3 with 33.23% which has a

combination of 30% mixture moisture content and 80:20 adlai:pineapple-carrots ratio. The

rest of the results are shown in Table 9. Analysis of variance states that the mixture

moisture content (P< 0.01), adlai:pineapple-carrots ratio (P< 0.10) and the interaction

between the variables (P< 0.01) are affecting extruded cereal moisture content.

Response surface regression yielded the following equation:

= 112.27139 2.150441 1.185582 + 0.03366712

36

The R-squared value is 0.9378 which is a good fit. Linear term was non-significant while

the quadratic term (P< 0.05) and two-function interaction (P< 0.01) was significant. The

contour plot analysis of extruded cereal moisture content as a function of mixture moisture

content and adlai:pineapple-carrots ratio in Figure 11 shows that the a high extruded cereal

moisture content is achieved by having a high adlai content and a high mixture moisture

content. This phenomena can be explained by the directly proportional relationship

between the addition of water and the increase in extruded cereals moisture content.

Figure 11. Contour plot for the extruded cereal moisture content as a function of

mixture moisture content and adlai:pineapple-carrots ratio.

Water Absorptivity Index. The values of water absorption index obtained from

the treatments were very close with each other. Water absorption index is a measuring

index of gelatinization. The highest water absorption index was that of treatment 1 with

3.00 g gel/g solids with a combination of 45% mixture moisture content and 60:40

37

adlai:pineapple-carrots ratio. The lowest water absorptivity index is treatment 4 with a

combination of 45% moisture content and a 80:20 adlai:pineapple-carrots ratio. A study

by Dorsey-Redding (1990) modelled the function of mixture moisture content against

water absorption index. The study concluded that an inversely proportional relationship

exists. The rest of the results are shown on Table 9. Studies made by Altan (2008) observed

that an increase in moisture content decreases the water adsorption index. The study

explained that the decrease in WAI is attributed to the competition of absorption of water

between pineapple pulp and the available starch. Analysis of variance shows mixture

moisture content (P< 0.01) and adlai:pineapple-carrots ratio (P< 0.01) are affecting the

water absorptivity index.

Response surface equation yielded the following equation:

= 5.99 0.06651 0.03282 + 5.010412

The R-squared value is 0.9436 which is a good fit. Linear (P< 0.01), quadratic (P< 0.05)

and twofactor interaction (P< 0.01) terms are significant. Contour plot analysis of water

absorptivity index as a function of mixture moisture content against adlai:pineapple-

carrots ratio on Figure 12 shows that the maximum water absorptivity index is achieved

with a low adlai content against pineapple-carrots content and a low mixture moisture

content. The study of Altan observed that there is a direct relationship between adlai

content against pineapple-carrots content exists until a critical point was reached. The

phenomena observed is due to the increase in the adlai in the sample consuming the

moisture. In effect, the adlai powder uses the excess moisture to create a paste until the

excess moisture is not accommodated anymore.

38

Figure 12. Water Absorptivity Index as a function of mixture moisture content

against adlai:pineapple-carrots ratio.

Chemical Analysis

Breakfast Cereal Final Moisture Content. The highest breakfast cereal final

moisture content was treatment 4 with 13.62% which has a combination of 45% mixture

moisture content and 80:20 adlai: carrots-pineapple ratio. The lowest final breakfast cereal

moisture content was achieved by treatment 1 with 8.08% which has a combination of

30% mixture moisture content and a 60:40 adlai: carrots-pineapple combination. The rest

of the results are shown on Table 9. Low moisture content will give the product a long

shelf life (Aremu, 2014). However, a more reliable measure of a long shelf life is water

activity but most cases, water activity and moisture content has a directly proportional

relationship. Analysis of variance suggests that mixture moisture content (P< 0.01) and

adlai:pineapple-carrots ratio (P< 0.01) are affecting the breakfast cereal final moisture

39

content. Response surface regression yielded the equation for breakfast cereal final

moisture content:

= 2.757 + 7.621031 + 0.13952 + 1.410312

The R-squared value is 0.9587 which is a good fit. The model is also significant

using linear (P< 0.01), quadratic (P< 0.01) and two-function interaction (P< 0.01) terms.

Contour plot analysis of breakfast cereal final moisture content as a function of the mixture

moisture content against adlai:pineapple-carrots ratio in Figure 13 shows that the

breakfast cereal final moisture content increases as the moisture content of the mixture has

been increased and the adlai content is increased against the pineapples-carrots powder

content.

Figure 13. Contour plot of breakfast cereal final moisture content as a function of

mixture moisture content and adlai:pineapple-carrots ratio.

40

The breakfast cereal final moisture content has a directly proportional relationship with the

amount of water added in the sample. The addition of adlai is also affecting the moisture

content by trapping the water as it is being used for gelatinization.

Crude Fat. The sample that was analyzed with the highest crude fat content is

treatment 1 with 4.06% with a combination of 30% mixture moisture content and a 60:40

adlai:pineapple-carrots ratio. The sample with the lowest crude fat is treatment 4 with

1.29% with a combination of 45% mixture moisture content and 80:20 adlai:pineapple-

carrots ratio. The rest of the data for fat content are shown on Table 9. Contour plot analysis

reveals that minimal water content and less adlai content against pineapple-carrots content

is needed to achieve a high fat content of sample. This increase may be caused by a

blending effect which affects the distribution of fat through the sample. A low fat content

is desirable for the product. Chemically, lipid oxidation is avoided due to rancidity of the

sample when stored especially that the treatments are in contact with metals in the extruder

barrel. Metals shavings are proved to accelerate oxidative rancidity. (Guy, 2000). Analysis

of variance revealed that mixture moisture content (P< 0.01) and adlai:pineapple-carrots

ratio (P< 0.05) affects the crude fat. This may be caused by the interaction of water

molecules available to the fat content particularly in adlai grains.

The response surface regression yielded the equation for crude fat:

= 17.001 0.31991 .128012 + 2.43310312

The R squared value is 0.9692 which is a good fit. The linear (P< 0.01), quadratic (P<

0.01) and two-function interaction (P< 0.01) are significant. Contour plot analysis of the

crude fat as a function of mixture moisture content against adlai:pineapple-carrots ratio

in Figure 14 shows that the less adlai:pineapple-carrots used in the sample and a lower

41

moisture content yields high fat content. Figure 14 states that a sample with the highest fat

can be obtained by combining a low moisture with a low adlai content against a high

pineapple-carrots content. A reason for a low crude fat may be due to the blending effect

of fat in the sample as explained by Kothakota (2013).

Figure 14. Contour plot for the crude fat as a function of mixture moisture content


Ash content. Ash content is the measure of all the matter left after ignition. It is

also a gross estimate of the mineral content that is available in the sample. The sample with

the highest ash content is treatment 1 with 5.81% which has a mixture moisture content of

30% and 60:40 adlai:pineapple-carrots ratio. The sample with the least ash content is

treatment 4 with an ash content of 1.22% which has a mixture moisture content of 45% and

80:20 adlai:pineapple-carrots ratio. The rest of the results are shown on Table 9. From the

study of Razzaq (2012). The extrusion cooking outcome is significant for nutrients like

42

calcium, iron and zinc. In this case, water dissolves the minerals that were carried by adlai,

pineapples and carrots thus reducing the ash content of the sample. Ash content may have

a direct relationship as pineapple and carrots are added. The proximate analysis of

pineapple and carrots shows significant values of nutrients against adlai and therefore may

be attributed in the increase in minerals as pineapples and carrots when coextruded with

adlai.

Response surface regression yielded the equation for ash content:

= 25.846 0.35201 0.24850 + 3.153310312

Figure 15. Contour plot for the ash content as a function of mixture moisture

content and adlai:pineapple-carrots ratio.

Analysis of variance reveals that mixture moisture content (P< 0.01) and adlai:pineapple-

carrots ratio (P< 0.01) affects the ash content. The R-squared value is 0.9182 which is a

good fit. The linear (P< 0.01) and two-function interaction (P< 0.01) terms are significant.

43

However the quadratic term is non-significant. Contour plot analysis of ash content as a

function of mixture moisture content against adlai:pineapple-carrots ratio in Figure 15

shows that the ash content yields maximum when the adlai:pineapple-carrots is decreased

and the mixture moisture content is increased. This phenomena can be explained by the

innate chemical build-up of pineapple-carrots against adlai content and a dilution effect of

the minerals available in the samples (Kothakota, 2013).

Crude protein. In the study, the protein content of the selected grain is significantly

needed to be studied. The inherent crude protein of the adlai grain is higher than standard,

conventional grains. The sample with the highest protein content is treatment 1 with

10.29% which has 30% mixture moisture content and a 60:40 adlai:pineapple-carrot ratio.

The least crude protein content with treatment 4 which has a 45% mixture moisture content

and 80:20 adlai:pineapple-carrots ratio. The rest of the results are shown on Table 9. Upon

looking at the results of protein content on Table 9 and the proximate analysis of adlai on

Table 2, there is a slight discrepancy of protein content between the raw powders against

that of the prepared breakfast cereals. This phenomena could be attributed to the cooking

technique. Prolonged cooking time under high temperature tends to lead to protein

denaturation and deamination reactions thus yielding a lower protein content. Mixture

moisture content also has an effect in the protein yield. According to Anuonye (2012), there

is a dilution effect of protein if a high moisture environment is present in the treatments.

Thus, a low moisture content tends to dilute much less protein against a higher mixture

moisture content. The moisture content also aids in cooking through convection by

affecting the protein content through protein denaturation. Another source of variances in

protein content is the innate chemical composition of the raw materials especially adlai

44

which has a relatively high amount of protein content against the pineapple-carrots powder

combination. This supports a directly proportional relationship exists between adlai

content and crude protein content. Analysis of variance revealed that the mixture moisture

content (P< 0.05) and adlai:pineapple-carrots ratio (P< 0.05) significantly affects the crude

protein content.

Response surface regression yielded the equation for crude protein:

= 18.40 0.03861 00678332 1.733010312

.

Figure 16. Contour plot of crude protein as a function of mixture moisture content


The R-squared value is 0.8240 which is a moderate fit. The linear term (P< 0.05) and two

function interaction (P< 0.05) significant. Quadratic process term is non-significant.

Contour plot analysis of crude protein as a function of mixture moisture content against

45

adlai:pineapple-carrots ratio in Figure 16 shows that a high crude protein is achieved by

having a low moisture content and having a low adlai content against a high amount of

pineapple-carrots powder. The results of the moisture content is consistent with the

findings of Anuonye which shows a higher yield of protein when less water is added in the

mixture.

Crude Fiber. Crude fiber is the rough estimate of insoluble starches such as

celluloses and hemicelluloses in the treatments. Crude fiber is one of the crucial

components of a breakfast cereal snack. Being a functional food, the benefit of having a

high fiber content is to increase fecal weight due to its indigestibility and to lessen the

contact time between intestines and fecal matter. In recent studies, residence time of feces

in the intestines may cause severe ailments particularly intestinal cancer. The sample with

the highest crude fiber content is that of treatment 1 with 6.04% which has a combination

of 30% mixture moisture content and 60:40 adlai:pineapple-carrots ratio. The lowest crude

fiber content is that of treatment 4 with 4.37% which has a combination of 45% mixture

moisture content and 80:20 adlai:pineapple-carrots ratio. The rest of the results are shown

on Table 9. Crude fiber is affected by the addition of the pineapple and carrots. The

proximate analysis of carrots and pineapple from Table 2 shows a relatively high amount

of fiber present in them. This explains the directly proportional relationship in the fiber

content of treatments with a higher pineapple-carrots content. Moisture also affects the

fiber content by diluting the treatments overall. This has an inversely proportional

relationship on the amount of fiber weight per weight in the sample. Analysis of variance

reveals that mixture moisture content (P< 0.01) and adlai:pineapple-carrots ratio (P< 0.10)

affects the crude fiber content.

46

Response surface expression yielded an expression for the crude protein.

= 39.707 0.85501 0.43102 + 9.7010312

The R-squared value is 0.8239 which is a moderate fit. Linear term (P

47

Carbohydrate content. The carbohydrate content using proximate analysis is a

function of the difference between the summations of previous chemical components. It is

also known as the Nitrogen Free Extract. This directly affects the carbohydrate content of

the samples relative to the other components included. The sample with the highest

carbohydrate content is treatment 4 with 77.83% which has 45% mixture moisture content

and a 80:20 adlai:pineapple-carrots ratio. The sample with the least carbohydrate content

is treatment 4 with 65.71% which has a 45% mixture moisture content and a 60:40

adlai:pineapple-carrots ratio. The rest of the data are shown in Table 9. In most of the study

by Anuonye (2012) and Kothakotha (2013), there has been no significant effect in the

carbohydrate content of the sample. Analysis of variance suggests the mixture moisture

content (P< 0.01) and adlai:pineapple-carrots ratio (P< 0.10) affects the carbohydrate

content.

Response surface regression yielded the equation for carbohydrate:

= 3.138 + 2.12011 + 0.81392 0.02316712

The Rsquared value is 0.8681 which is a moderate fit. Linear term (P< 0.01) and two-

function interaction (P< 0.05) are significant while the quadratic process term is not-

significant. Contour plot analysis of carbohydrates as a function of mixture moisture

content and adlai:pineapple-carrots ratio in Figure 18 shows an increase in adlai content

against pineapple-carrots content and a high mixture moisture content yields the highest

carbohydrate content. This is due to the increase in adlai which has a high total

carbohydrate content (Vilbar, 2014). However, the moisture also affects by aiding

molecular dispersion and gel formation which converts some starches into carbohydrates

(Fennema, 2014).

48

Figure 18. Contour plot of carbohydrates as a function of mixture moisture

content against adlai:pineapple-carrots ratio.

Sensory Evaluation

Sensory evaluation of the prepared breakfast cereal snacks was conducted at the

Food Science Cluster. Twenty (20) panelist determine the eating quality of the product.

Based on quality scoring, the attributes such as: appearance, taste, aftertaste, texture and

General acceptability were evaluated.

Appearance. The sample with the highest score in appearance was treatment 2

with a score of 6.20 which has a moisture content of 45% and an 60:40 adlai:pineapple-

carrots ratio. The least score for appearance was treatment 8 with a score of 4.4 which has

a 35% mixture moisture content and 80:20 adlai:pineapple-carrots ratio. The rest of the

results are shown on Table 10. Upon looking at the appearance of the treatments, a trend

has been observed in the different treatments. A browning effect has been observed with

49

less adlai in the mixture and more of the pineapple-carrots mixture. This may be attributed

as oxidative browning or maillard reaction of the carrots mixture and the pineapple powder

components. A mixture with more adlai in the sample tends to be whiter. Adlai components

tends to dominate the appearance of the sample upon gelatinization. Analysis of variance

revealed that adlai:pineapple-carrots ratio (P< 0.05) affects the appearance of the samples.

Figure 19. Contour plot of appearance as a function of mixture moisture content

against adlai:pineapple-carrots ratio

.


= 10.38633 0.252441 0.093332 + 4.1333310312.

The R-squared value is 0.7153 which is a moderate fit. Linear, two-factor interaction and

quadratic terms shows that the terms are not significant. Contour plot analysis of

appearance as a function of mixture moisture content against adlai:pineapple-carrots ratio

on Figure 19 shows that a higher pineapple-carrots content against adlai content is

generally preferred by judges due to a more brownish color of the final product. This is in

agreement with the results of Guy which prefer a brownish color. The brownish color of

50

the samples signify that the samples are well dried, and near the appearance of

commercially prepared breakfast cereal snacks. Moisture content affects the appearance

through plastization which lubricates and fully separates and solvate amylose chains thus,

showing more air packets in the sample which is formed through drying of the extrudates

which may have been increased the quality score of products with high moisture content.

(Fennema, 2014).

Flavor. The treatments with the highest score is treatment 1 which has a 30%

moisture content and a combination of 60:40 adlai:pineapple-carrots ratio. The lowest

score is treatment 8 which has 35% moisture and 80:20 adlai:pineapple-carrots ratio. The

rest of the results are shown on Table 10. A trend has been observed in the samples.

Treatments with more carrots-pineapple in their composition tends to bring a hint of

sourness on it. This is due to the powdering process of pineapple which tends to crystallize

the sugars in the sample. However, acids in pineapple are also concentrated which explains

the perceived sourness on the samples. Analysis of variance reveals that the interaction of

moisture and adlai:pineapple-carrots ratio (P< 0.05) affects flavor of the product.


() = 22.696 + 0.688971 + 0.378932 9.334410312

The R-squared value is 0.6794 which is a moderate fit. There were no significant

terms. The contour plot analysis of flavor as a function of mixture moisture content against

adlai:pineapple carrots in Figure 20 shows that the highest scores in flavor were achieved

using a high mixture moisture content and a high adlai content, and that of a high mixture

moisture content and a low adlai ratio. In this case, mixture moisture content, have affected

the flavor of the product. From observation of the contour plot, the highest scores were

51

achieved with both a high mixture moisture content with a low pineapple-carrots content

against adlai and a high adlai content with a low moisture content. This result may be due

to the trend of the judges as to perceive the tartness as an off-taste.

Figure 20: Contour plot of flavor as a function of mixture moisture content against

adlai:pineapple-carrots ratio.

An increase in adlai content neutralizes the taste of such a high concentrate product as the

pineapple. This is also the same as increasing the moisture content to dilute the sugars and

acids brought by the pineapple in the treatments.

Aftertaste. The sample with the best score for aftertaste is treatment 6 with 5.27

which has a 45% moisture and a 70:30 adlai:pineapple-carrots. The sample with the least

score for aftertaste was treatment 1 with 30% mixture moisture content and 60:40

optimization of formulation for breakfast snacks using adlai (coix lacryma-jobi l.), pineapple...

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