Recovered residue from corn flake processing and its application in modified flours and arepa bread

Area of Science:

• Food Science
• Material Science
• Chemical Engineering

Background:

• Corn flake processing generates significant residue, posing a waste management challenge.
• Valorization of this residue through modification and incorporation into food products is an area of interest for sustainability.
• Previous studies have explored various modification techniques for food byproducts.

Purpose of the Study:

• To characterize corn flake processing residue and its modified flours (extruded, heat-moisture treated).
• To evaluate the physicochemical and technological properties of the modified flours.
• To assess the sensory acceptance and purchase intent of arepa bread formulated with the modified flour.

Main Methods:

• Corn flake residue was modified using extrusion, heat-moisture treatment (HMT) in an oven, and HMT in a direct-steam autoclave.
• Physicochemical properties (particle size, color, viscosity, water absorption/solubility) and thermal properties (transition temperature, enthalpy) were analyzed.
• Arepa bread was formulated with varying ratios of residue and extruded residue flour (ERF), followed by sensory evaluation.

Main Results:

• Extruded residue flour (ERF) was classified as a medium flour with desirable color (high b* and C* values) for baked goods.
• ERF exhibited excellent functional properties, including high cold viscosity, water absorption, and water solubility, suitable for gluten-free products.
• Arepa bread with 70% residue and 30% ERF (PA30) achieved high sensory acceptance (77% acceptability index) and a good macronutrient profile.

Conclusions:

• The utilization of corn flake residue and its extruded modified flour in arepa bread is technically feasible.
• This application offers a sustainable pathway to add value to corn industry byproducts.
• The developed arepa bread formulation presents a promising gluten-free product with good sensory attributes.