Formulation of pea-based inks with different starches to produce customized 3D printed and baked snacks

The technique of 3D food printing offers the exciting potential to create customized foods. The study aimed to examine how varying composition (using different starch types) affects the 3D printability of formulations and the texture of customized pea-based snacks after post-processing. Edible inks containing a mixture of insoluble pea fibre, pea protein, and different starch types (i.e., native pea starch, pre-gelled pea starch, and potato flakes) were formulated by adding water based on ingredients' water holding capacity (WHC) and evaluated for printability. Furthermore, the printed products were baked at 175 °C for 5, 10, and 15 min to evaluate the fracture behaviour of the post-processed products. Results showed that potato flakes had the highest WHC, followed by pre-gelled pea starch and native pea starch, owing to their microstructural differences. The WHC approach proved effective in arriving at printable samples irrespective of the changes in starch type. Moreover, the range of extrudable formulations with varying ingredient concentrations was broadened when pre-gelled pea starch and potato flakes were used. Microstructural analysis of fresh inks and baked samples indicated that native starch granules partially gelatinized during baking, while all samples showed different levels of dehydration during the baking process based on changes in moisture content. Despite the physicochemical differences that exist between the starch types, fracture properties were largely controlled by baking time. The knowledge gained from this study can facilitate a systematic approach to effectively formulate personalized plant-based foods of desired quality and texture using 3D food printing.