New functional extruded products based on corn and lentil flour formulated with winemaking by-products

Authors: CATACALLAPA, MARIO - Complutense University Of Madrid (UCM); Berrios, Jose; Pan, James; Alves Buongiorno, Priscila; ARRIBAS, CLAUDIA - Complutense University Of Madrid (UCM); PEDROSA, MERCEDES - Complutense University Of Madrid (UCM); MORALES, PATRICIA - Complutense University Of Madrid (UCM); CAMARA, MONTANA - Complutense University Of Madrid (UCM)

Submitted to: Processes
Publication Type: Peer Reviewed Journal
Publication Acceptance Date: 5/15/2025
Publication Date: 5/22/2025
Citation: Catacallapa, M.S., Berrios, J.D., Pan, J., Alves Buongiorno, P.L., Arribas, C., Pedrosa, M.M., Morales, P., Camara, M. 2025. New functional extruded products based on corn and lentil flour formulated with winemaking by-products. Processes. 13(6). Article 1635. https://doi.org/10.3390/pr13061635.
DOI: https://doi.org/10.3390/pr13061635

Interpretive Summary: The current high demand for food presents a challenge for the food industry to produce innovative and functional food products that meet consumers' expectations for convenience, taste, health benefits, affordability, and sustainability. By-products from various food and beverage processing streams, such as the wine industry, contain valuable nutrients that can be used to develop new food products and improve the overall sustainability of the food chain. To enhance the nutritional value of food products, new functional extruded products have been developed based on combinations of corn and lentil flour, fortified with winemaking by-products. These new products were formulated using a corn-based mix (70:30) at different ratios (93.75% to 53.75%), with added salt (1.25%), sugar (5%), and Hylon® V (5-20%), and fortified with fermented Cabernet Sauvignon skin/seed or unfermented Chardonnay seed (5-20%). The extrusion cooking process involved specific conditions of feed moisture, feed rate, screw speed, and die temperature. The developed products in the form of snacks were analyzed mainly for different types of fibers, starch and other carbohydrates. Results showed that the products fortified with 20% of winemaking by-products had increased fiber, antioxidants, and resistant starch content, and a decreased in total available carbohydrates and oligosaccharides compared to their control, making them valuable as functional foods. These new food products offer lower caloric value, which can help in maintaining healthy cholesterol and blood glucose levels, with potentially reduced undesirable gaseous effect often associated with legume-based foods.

Technical Abstract: The current high demand for food presents a challenge for the food industry to produce innovative and functional food products that meet consumers' expectations for convenience, taste, health benefits, affordability, and sustainability. By-products from various food and beverage processing streams, such as the wine industry, contain valuable nutrients that can be used to develop new food products and improve the overall sustainability of the food chain. To enhance the nutritional value of food products, new functional extruded products have been developed based on combinations of corn and lentil flour, fortified with winemaking by-products. These new products were formulated using a corn-based mix (70:30) at different ratios (93.75% to 53.75%), with added salt (1.25%), sugar (5%), and Hylon® V (5-20%), and fortified with fermented Cabernet Sauvignon skin/seed or unfermented Chardonnay seed (5-20%). The extrusion process involved specific conditions of feed moisture (17%), feed rate (25 kg/h), screw speed (500 rpm), and die temperature (160°C). The extruder die opening had a diameter of 3.5 mm. The developed extrudates were analysed mainly for fibre, arabinoxylans, starch and oligosaccharides content. Results showed that extruded products fortified with 20% of winemaking by-products had increased fibre, arabinoxylans, phenolic compounds, and resistant starch content, and a decreased in total available carbohydrates and oligosaccharides compared to their control, making them valuable as functional foods. These new food products offer lower caloric value, which can help in maintaining healthy cholesterol and blood glucose levels, with potentially reduced undesirable gaseous effect often associated with legume-based foods.