Sugar inclusion influences the expansion characteristics of corn starch extrudates

Corn starch-based direct expanded products incorporated with 2% and 10% (w/w) sugar (fructose, glucose, sucrose, and xylose) were produced using a 20 mm co-rotating twin-screw extruder. The pasting and thermal properties of raw corn starch-sugar mixes were analyzed before extrusion processing. The independent variables for extrusion processing included two sugar inclusion levels (2% and 10% w/w) and two screw speeds (150 and 250 rpm). The extrudates were characterized by their initial expansion ratio (IER), expansion ratio (ER), and shrinkage. ER values were high for fructose at 2% and 150 rpm and 10% glucose and sucrose extrudates at 250 rpm. The extrudates with 2% sucrose inclusion shrunk significantly higher than the control. Fourier transform infrared (FTIR) spectroscopy of the extruded blends did not indicate the presence of any new covalent bond formed between starch and sugar post-extrusion. The interactions between sugar concentration and screw speed significantly influenced extrudate expansion characteristics. Due to their thermal and plasticizing properties, sugar inclusion (glucose, fructose, sucrose, and xylose) enhanced the extrudate expansion by altering their melt viscosity. PRACTICAL APPLICATION: The findings of this study can improve the expansion characteristics of high-fiber-based extruded snacks. Ingredients high in fiber generally hinder the starch transformation during extrusion and negatively impact the expansion properties. The presence of sugar at low concentrations can improve melt properties during extrusion processing and, in turn, significantly improve the textural properties of snacks.