Process Optimization and Storage Evaluation of Explosion Puffing Dried Reduced-Fat White Cheese Snacks.

Area of Science:

• Food Science and Technology
• Dairy Processing
• Novel Food Product Development

Background:

• Previous research identified microwave + freeze hybrid drying (MD + FD) as optimal pre-drying for reduced-fat white cheese (RFWC) snacks.
• A target moisture content of 45 g/100 g was established for RFWC samples prior to explosion puffing drying (EPD).

Purpose of the Study:

• To optimize the explosion puffing drying (EPD) process parameters for producing high-protein RFWC snacks.
• To evaluate the impact of EPD variables on protein content, crispness, volumetric expansion, and sensory acceptability.
• To assess the 6-month shelf stability of the optimized high-protein cheese snacks.

Main Methods:

• Response surface methodology (RSM) with a Box-Behnken design was employed to optimize EPD parameters.
• Independent variables included puffing temperature, puffing time, and vacuum temperature.
• Protein content, crispness, volumetric expansion, and sensory scores were measured as responses.

Main Results:

• Vacuum temperature significantly influenced all evaluated responses.
• Puffing time was critical for protein content and crispness; puffing temperature affected volumetric expansion.
• Optimal EPD conditions (100°C puffing, 5 min puffing, 60°C vacuum) yielded 60.33 g/100 g DM protein, 34.40 crispness, 16.60% expansion, and a sensory score of 7.46.
• Snacks maintained quality for 4 months, with degradation observed from month 5.

Conclusions:

• Explosion puffing drying (EPD) is a viable method for creating high-protein, crispy cheese snacks with desirable sensory attributes.
• Optimal EPD parameters significantly enhance product quality and nutritional value.
• Appropriate packaging is crucial for maintaining snack stability and extending shelf life beyond 4 months.