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Journal of Food Science and Technology logoLink to Journal of Food Science and Technology
. 2021 Jan 2;58(5):2034–2040. doi: 10.1007/s13197-020-04940-2

Quality characteristics of buckwheat (Fagopyrum esculentum) based nutritious ready-to-eat extruded baked snack

Sarwar Iqbal 1, M P Thanushree 1, M L Sudha 1, K Crassina 1,✉
PMCID: PMC8021665  PMID: 33897040

Abstract

The study aimed to utilize buckwheat and bread waste to develop ready to eat snack with reduced fat, enriched protein, dietary fiber and minerals. Base flour constituting of buckwheat flour (BF) and rice flour in the ratio of 90:10 was replaced with bread powder (BP) at varying levels (0–80%). The gelatinization temperature of base flour was 67 °C and it decreased with increasing amount of BF. The breaking strength of the extruded snack with varying amount of BP, fat and chilli powder were in the range between 3.46–2.04 N, 1.56–1.26 N and 1.5–1.89 N respectively. Physical and sensory analyses indicate that 40% BP, 8% fat and 1% chilli powder were optimum to obtain extruded snack with desirable characteristics. The ready to eat snack contained 10.64%, 15.33% and 7.45% of fat, protein and total dietary fiber respectively. Minerals present were 169 mg/100 g of magnesium, 46 mg/100 g of calcium, 4.5 mg/100 g of iron and 3.46 mg/100 g of zinc. Bread waste can thus be utilized in producing a healthy ready to eat snack.

Keywords: Ready-to-eat snack, Buckwheat, Bakery waste, Pasting characteristics, Dietary fiber

Introduction

Food wastage is a widespread global problem, posing challenge in food security, food safety, the economy, and environmental sustainability. According to Food and Agriculture Organization (FAO) of the UN, approximately one third of the food produced for the human consumption, amounting to 1.3 billion tones, gets lost or wasted. The organization’s SAVE FOOD initiative works with civil society to address the issue (FAO 2018).

Bread is a staple food and has been a prominent food in many parts of the world and is the most common baked product produced in large amounts. The estimated wastage for bakery products ranges from 7 to 10% of its total production. Many countries have reports on bread wastage accounting for a significant economic loss (Gayton 2019). Usually a significant part of the waste results from defects such as deformations and under/over-baking during processing and from the unsold breads in both small scale and industrial bakeries (Turkish Grain Board; TMO 2015). Often in industrial bakery set-up, bread waste is added along with other ingredients in the making of bread or other products. Especially the ones with deformations are dried, ground and sieved and marketed as “bread crumbs”. Bread crumbs are extensively used for making a crisp and crunchy coating in fried/baked foods.

Ready-to-eat snacks are among the most popular foods which are accepted by large number of consumers due to their convenience, appeal and texture. It can be sweet, salted, fried, baked and extruded depending on the formulation and processing methods. Most of the conventional snacks are usually high in fat and calorie. According to a survey, children in the North America eat snacks on an average of six times per day (Statista 2014). Governmental departments like Health Canada is recommending people to eat healthier and nutritious snack (SMART SNACKING 2011). Apart from the usual deep fried savories or bakery snacks like biscuits, cookies, cakes etc.; baked snack of other forms can be an alternative in producing ready-to-eat snacks with lower fat and sugar. Recent study by Soumya et al. (2019) stated that heat treated whole-wheat flour can be used to produce baked snack with desired characteristics having low fat.

Buckwheat has gained much interest owing to the healing and preventive roles in various non-communicable diseases. Buckwheat is also a potential material for formulating low glycemic index food as it has high resistant starch at 33.5–37.8% of its total starch (Skrabanja et al. 1998). Besides, buckwheat is a rich source of bioflavonoids especially rutin (Guo et al. 2007; Kreft et al. 1999) which is known to have many health benefits and successfully treat seasonal allergy, increase vascular elasticity and prevents internal bleeding (Gawlik-Dziki et al. 2009), reduce blood glucose level and have high antioxidant activity (Zhang et al. 2010).

Many works have been done for the processing parameters, physical and sensory characteristics of snack foods. However, utilization of bread waste in ready-to-eat snack is rare. The present work aims to utilize buckwheat in combination with bakery waste so as to produce extruded ready-to-eat baked snack containing good amount of fiber, minerals with low fat.

Materials and methods

Buckwheat flour (BF) and bread powder (BP)

Commercially dehulled common buckwheat (Fagopyrum esculentum) groats were procured form the local market. The groats were milled into flour (BF) with particle size of 150 µm using a mini- laboratory mill (Falling Number LM3100, Perten Instruments, Belgium).

Bread sample was prepared using a lean formulation for uniform quality. Commercial refined wheat flour of medium strong type having 12.46% moisture and 9.5% total dry gluten was used for bread making. The breads were sliced and dried in a hot air oven at 100 °C for 3–4 h. The dried bread sample was then ground to fine powder using food processor to obtain bread powder (BP) to be used as bread waste.

The ingredients namely rice flour (RF), salt, butter, baking powder, spices (ajwain and chili powder) were procured from local market.

Chemical characteristics

Standard methods of AACC 2000 were followed to determine moisture (method 44–16), gluten (method 38–10), protein (method 46–10), crude fat (method 30–10) and ash (method 08–01) of raw materials and extruded snack.

Amylograph

Standard method of AACC 2000 (method 22–10) using Micro-Visco-Amylograph (803201 Type Brabender, Germany) was followed for measuring the pasting properties of base flour (90 BF + 10RF) with varying levels (0–80%) of bread powder (BP). The paste parameters namely gelatinization temperature, peak viscosity, set back and break down were evaluated. All parameters were measured in Brabender units (BU).

Determination of soluble dietary fiber (SDF), insoluble dietary fiber (ISDF) and total dietary fiber (TDF)

The SDF, ISDF and TDF were determined for the raw materials as well as the optimised extruded ready-to-eat snack. Enzymatic–gravimetric method of AOAC 991.43 (AOAC 2005) was followed. Defatted samples were suspended in MES-TRIS buffer and digested sequentially with heat stable α- amylase, protease and amyloglucosidase enzymes. To obtain the ISDF, the digested samples were filtered through silica crucibles with fritted disk of porosity 46-60 µm. For the SDF, the filtrate was precipitated for 1 h by adding 96% ethanol previously warmed to 60 °C and filtered similarly as for ISDF. Total dietary fiber was obtained by adding ISDF and SDF. Residues were corrected for nitrogen and inorganic matter content.

In-vitro starch digestibility

The method of Holm et al. (1986) was adopted to determine the in-vitro starch digestibility. 100 mg of sample was suspended in 10 ml H2O. pH was adjusted to 6.9–7 with NaOH (0.2 M). Then 3 mL of α- amylase (A3176, 10 units/mg solid, Sigma, St. Louis, MO USA) solution was added and incubated at 37 °C for 2 h. Further, 15 mL of 0.2 M glycine–HCL (pH 2.0) containing 15 mg pepsin was added and incubated at 37ºC for 2 h. At the end of the period, pH was adjusted to 6.9–7.0 with 0.2 M NaOH, and 15mL 0.05 M phosphate buffer (pH 6.9) containing 15 mg pancreatin (P7545, activity equivalent to 8 × U.S.P specifications; Sigma) were added and incubated at 37 °C for 2 h. After completion of incubation, pH was adjusted to 4.6 with dilute acetic acid. Then 15 mL acetate buffer of pH 4.5 containing15mg of amyloglucosidase (A7255, 22,500 units/g solid, Sigma) was added and the mixture was incubated at 37 °C for 2 h. Final mixture was made up to 100 mL with water and filtered before estimation. Glucose was estimated using the glucose oxidase/peroxidase (GODPOD) diagnostic kit (Mediclone Biotech Pvt. Ltd, Chennai, India). Glucose standard was prepared (20–60 mg/dl) to get the standard curve (Y = 0.0109 × − 0.0036). The absorbance was read using UV–VIS-1800 spectrophotometer (Shimadzu, Japan) at 505 nm. Percentage of starch digestibility was calculated as percent starch hydrolyzed from the total starch content in the sample (% digestibility = starch digested/ total starch × 100).

Determination of minerals content

The content of minerals namely sodium, magnesium potassium, calcium, iron, zinc, manganese and copper were estimated using atomic absorption spectrophotometer methods (Ranganna 1986). Ashed samples were acid digested with hydrochloric acid and diluted to a known volume. Appropriate test parameters such as resonant wavelength, slit width and air-acetylene flow rate for each element were selected. A range of working standards of each element was also prepared to get the calibration curve. Test solution was aspirated and the concentration of the element was determined. The analysis was carried out in triplicates and the average values are reported.

Preparation of ready-to-eat extruded snack

Initial trials were carried out to arrive at the experimental level of buckwheat flour (BF) and rice flour (RF) in the proportion of 90:10. Extruded ready-to-eat snacks were prepared using the formulation as follows: base flour-100 g, varying levels of bread powder (0, 20, 40, 60, 80%), varying levels of fat (6, 8, 10%) to the optimized level of bread powder (40%), varying levels of red chilii powder (1, 2, 3%) to the optimized level of fat (8%), baking powder-1 g; table salt-1 g, ajwan-0.5 g, water-60–70 ml. The percentage of bread powder, fat and chilli are taken on base flour basis. Respective proportions of the dry ingredients were mixed in a planetary mixer (Model N50 Hobart, Germany) for 5 min. The required amount of water was added to obtain a dough which could be extruded easily in a hand extruder (circular die of 5 mm diameter, Murukku Maker AL-30 Lakshmi Cookware, India). The extruded strands of about 6 cm were then baked in the deck oven (Rotel, APV Inc., Queensland, Australia) at 220 °C for 20–30 min.

Physical and sensory characteristics

Diameter

Diameter of the snacks was determined using Vernier calipers. The technique for measurement is to first read the main scale to the nearest division and then the Vernier scale to measure the distance between the two main scale divisions which provide more accurate measurements.

Color measurement

The color values of baked extruded ready-to-eat snack samples were measured in terms of lightness (L = 100: white, L = 0: black) and color (+ a: red, -a: green, + b: yellow, -b: blue) using Hunter L a b spectrocolorimeter (Model Labscan, XE, Reston USA). A standard white board made from barium sulphate (100% reflectance) was used for setting the instrument with illuminant D.

Texture Analysis

The breaking strength of snacks was measured by following triple beam snap technique using a food texturometer (TA-HDi, Stable Micro System, Surrey, UK) according to the method mentioned by Gains, 1991. The sample was rested on two supporting beams spread at a distance of 4 cm. Another beam connected to a moving part was brought down to break the snack at a cross head speed at 10 mm/ min using a 10 kg load cell. The peak force (g) at break, representing breaking strength, was recorded and the mean values of triplicates are expressed.

Sensory characteristics

Sensory characteristics of snacks was carried out by a group of 10 male and 10 female panelists in the age group of 25 and 50 years who had earlier experience in the quality evaluation of baked products. The samples were presented with three-digit code numbers in a random order to the panelist and were asked to score for various sensory attributes namely appearance, texture, mouthfeel and overall quality on a 9-point hedonic scale (Hooda and Jood, 2008).

Statistical analysis

Statistical analysis for the physical and sensory data was performed using Duncan’s New Multiple Range Test (Duncan 1955). A significance level of 5% was adopted for the comparison.

Results and discussion

Pasting properties

Pasting properties of base flour (90BF + 10RF) with different levels (0–80%) of bread powder is presented in Fig. 1. The gelatinization temperature which indicates the minimum temperature required to cook was in the range of 32–67 °C. The maximum gelatinization temperature (67 °C) was seen in base flour with 0% BP and it decreased with increasing amount of BP, with the minimum value (32 °C) in 80% BP. This shows that the heat energy required to gelatinize the native uncooked starch granules in the base flour is more as compared to the cooked starch in bread powder. A significant difference was observed in the peak viscosity values of the blends. Peak viscosity is a measure of the water holding capacity of the starch in terms of the resistance of swollen granules to shear force and the ability of the starch granules to freely swell before their physical breakdown for the base flour was 1329BU. De Francischi et al. (1994) reported buckwheat flour had three times the peak viscosity of wheat flour. As the level of bread powder increased the peak viscosity decreased with the lowest value (475BU) at 80% bread powder and this may be attributed to the lower viscosity of starch granules present in bread powder as compared to those present in buckwheat flour. Earlier reports show that the maximum viscosity of wheat flour ranges from 390 to 897BU (Mohan Kumar et al. 2014; Ramya et al. 2016; Thanushree et al. 2017). The break down which is regarded as a measure of degree of disintegration of the granules decreased from 2017BU to as low as 2BU as the bread powder increased from 0 to 80%. The setback values which indicate the retrogradation of gelatinized starch granules decreased from 535 to 369 BU with increase in BP. This reduction is due to the interaction of swollen starch granules of base flour and bread powder making the swollen granules more fragile and gel into a semi solid paste while cooling. Appearance of small peak in sample ‘a’, wherein no bread powder is added, could be due to the interactions of solubilized amylose with lipids and protein denaturation (Abd Karim et al. 2000). Later, with addition of increasing levels of bread powder, plateauing of peak was observed and after the small fall in viscosity, during the cooling phase, re-association of starch granules occur which is called as the retrogradation of the starch granules. The decrease in peak viscosity with addition of bread powder suggests a decrease in water-holding capacity and granule swelling ability (Marti et al.2010).

Fig. 1.

Fig. 1

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Effect of bread powder (BP) on the amylograph characteristics of base flour (90 Buckwheat Flour + 10 Rice Flour). A-0% BP, B-20% BP, C-40% BP, D-60% BP, E-80% BP

Quality characteristics of baked extruded ready-to-eat snack

With increase in the level of bread powder, the diameter of the snack increased from 3.95 to 4.62 mm (Table 1). The texture values decreased from1.56 to 1.26 N indicating the snack was becoming crispy with increase in the bread powder. The softer texture of the snack is attributed to the presence of pre-gelatinized, swollen and porous starch granules from the bread powder. With increase in the bread powder, the surface color became more brownish and crispier. The snack had a prominent bread flavor and taste beyond 40% of bread powder incorporation. Hence, incorporation of bread powder at 40% was considered optimal and was used to study the further variation of fat (6–10%) and chilli (1–3%). Addition of increasing levels of fat improved the palatability of the product. The diameter of the snack increased from 4.35 to 4.86 mm. Crassina and Sudha (2015) in their study on use of mango ginger powder in soupsticks, observed that with increase in breaking strength values, the texture of soupsticks becomes harder. The color values presented in Table 1 shows that there was a marginal change in the L, a, b values with varying levels of fat. Based on the texture values and sensory attributes, 8% fat was considered optimum.

Table 1.

Physical and sensory characteristics of extruded snack with variations of bread powder, fat and chilli

Variations Diameter (mm) Texture (N) Color Sensory attributes
L a  b Appearance (9) Texture (9) Mouthfeel (9) Overall quality (9)
BP (%)
0 3.95 ± 0.05b 3.46 ± 00a 56.12 ± 0.86c 4.64 ± 0.01a 15.14 ± 0.02e 7d 6.5d 6c 7b
20 4.55 ± 0.05a 3.22 ± 0.06b 60.83 ± 0.01b 3.48 ± 0.03b 17.48 ± 0.01d 7 d 7bc 6.5b 7b
40 4.62 ± 0.02a 2.93 ± 00c 60.94 ± 0.01b 3.38 ± 0.03c 17.82 ± 0.03c 7.5c 7.5b 7a 8a
60 4.57 ± 0.01a 2.49 ± 0.02d 62.69 ± 0.01a 2.76 ± 0.02d 18.46 ± 0.06b 8b 8a 6.5b 7b
80 4.61 ± 0.01a 2.04 ± 0.01e 63.49 ± 0.01a 2.35 ± 0.02e 18.88 ± 0.01a 8.5a 7c 6c 6c
*Fat (%)
6 4.35 ± 0.01c 1.56 ± 0.02a 62.95 ± 0.01a 1.48 ± 0.03b 13.59 ± 0.01c 7a 6.5c 6c 6.5c
8 4.57 ± 0.02b 1.42 ± 0.02b 61.64 ± 0.02b 1.53 ± 0.01b 14.83 ± 0.01b 7a 7b 7b 7.5a
10 4.86 ± 0.02a 1.26 ± 0.01c 60.73 ± 0.01c 2.05 ± 0.03a 15.28 ± 0.02a 7.5a 8a 7.5a 7.5b
**Chilli (%)
1 4.39 ± 0.03a 1.5 ± 0.01c 57.17 ± 0.16a 8.98 ± 0.01c 19.35 ± 0.01b 7.5a 7a 7.5a 7.5a
2 4.43 ± 0.02a 1.72 ± 0.02b 53.5 ± 0.02b 12.25 ± 0.02b 21.13 ± 0.06a 7.5a 7a 6b 7b
3 4.45 ± 0.01a 1.79 ± 0.01a 49.35 ± 0.03c 14.80 ± 0.01a 20.97 ± 0.10a 7.5a 7a 6b 7b
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*40%BP, **40% BP + 8% fat

BP bread powder, N Newton L lightness/darkness, ± a: red/green, ± b: yellow/blue, Values are means ± standard deviation (n = 3), Values in the same column with different superscript letters are significantly different at p < 0.05

To make the snack more palatable, different levels of chili powder was used in the study. There was a marginal change in the L, a, b values (Table 1) with varying levels of chili powder. L, which represents the lightness value decreased, the redness value (+ a) increased with addition of chili. The yellowness value (+ b) was between 15 and 20 indicating of slight yellowish color of the snacks. The texture values did not vary significantly. Sensory evaluation of the snacks with different levels of chilli powder indicated that 1% addition of chilli powder was optimum beyond which it tasted slightly pungent and spicy.

Nutritional composition of raw materials and extruded ready-to-eat snack

The proximate composition of the raw materials and optimized snack is presented in Table 2. The buckwheat flour (BF) contained 10.97 ± 0.22%, 1.55 ± 0.01%, 2.15 ± 0.01%, 16.01 ± 4.1% whereas in the bread powder (BP) 8.29 ± 0.05%, 1.59 ± 0.01%,  3.0± 0.12%, 13.83 ± 2.3% of moisture, ash, fat and protein respectively. The moisture, ash, fat and protein content in the rice flour used in the study were 10.85 ± 0.14%, 0.24 ± 0.02%, 0.68 ± 0.16% and 7.72 ± 1.67% respectively.

Table 2.

Nutritional composition of raw materials and extruded snack

Parameters Bread powder (BP) Buckwheat flour (BF) Rice flour (RF) Extruded snack
Moisture (%) 8.29 ± 0.05 10.97 ± 0.22 10.85 ± 0.14 3.68 ± 0.02
Ash (%) 1.59 ± 0.01 1.55 ± 0.01 0.24 ± 0.02 1.20 ± 0.02
Fat (%) 3.0 ± 0.12 2.15 ± 0.01 0.68 ± 0.16 10.64 ± 0.23
Protein (%) 13.83 ± 2.3 16.01 ± 4.1 7.72 ± 1.67 15.33 ± 2.56
Total starch (%) 70.68 ± 5.12 61.51 ± 0.5 80.23 ± 3.01 55.15 ± 0.01
In-vitro starch digestibility (%) 48.88 ± 5.26 34.83 ± 5.05 56.79 ± 2.23 47.20 ± 6.95
Insoluble dietary fiber (%) 2.08 ± 0.03 4.67 ± 1.5 0.64 ± 0.02 6.03 ± 0.22
Soluble dietary fiber (%) 0.42 ± 0.01 3.09 ± 0.26 0.28 ± 0.03 1.42 ± 0.41
Total dietary fiber (%) 2.5 ± 0.05 7.76 ± 1.68 0.92 ± 0.18 7.45 ± 2.54
Sodium (mg/100 g) 204 ± 6.0 12 ± 4.0 1.6 ± 4.0 231 ± 3.0
Magnesium (mg/100 g) 38 ± 0 220 ± 4.0 4 ± 0.0 169 ± 1.0
Potassium (mg/100 g) 179 ± 5.0 392 ± 8.0 38 ± 4.0 373 ± 9.0
Calcium (mg/100 g) 56 ± 2.0 40 ± 6.0 14 ± 4.0 46 ± 0
Iron (mg/100 g) 2.6 ± 1.4 6.8 ± 0.6 0.2 ± 1.2 4.5 ± 1.6
Zinc (mg/100 g) 0.6 ± 2 3.5 ± 2.0 1.4 ± 0 3.46 ± 1.0
Manganese (mg/100 g) 0.99 ± 0.01 1.5 ± 0.5 0.8 ± 0.2 1.1 ± 0.2
Copper (mg/100 g) 0.3 ± 0.0 0.8 ± 0.0 0.30 ± 0.21 0.5 ± 0.0
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Values are means ± standard deviation (n = 3)

The optimized snack having 40% BP, 8% fat and 1% chilli powder contain 3.68 ± 0.02% moisture, 1.20 ± 0.02% ash, 10.64 ± 0.23% fat and 15.33 ± 2.56% protein. The nutritionally important chemical composition of raw materials and snack is presented in Table 2. With respect to total starch content in the raw materials, the highest was exhibited by RF (80.23 ± 3.01%) followed by BP (70.68 ± 5.12%) and BF (61.51 ± 0.5%) with percent digestibility of 56.79 ± 2.23%, 48.88 ± 5.26% and 34.83 ± 5.05% respectively. In case of the snack, the starch content was 55.15 ± 0.01%, of which 47% is in-vitro digestible.

In case of dietary fiber, the highest amount was seen in BF with 4.67 ± 1.5% ISDF, 3.09 ± 0.26% SDF and 7.76 ± 1.68% TDF. It was observed that the snack contained good amount of ISDF (6.03 ± 0.22%), SDF (1.42 ± 0.41%) and TDF (7.45 ± 2.54%). The developed snack can be said as rich in fiber as it meets the recommendations made by FSSAI (F.No.1-94/FSSAI/SP (Claims and Advertisements/2017) and EU standards [Regulation (EC) No 1924/2006] which require a minimum 6 g of fiber/100 g sample for claim of high fiber in food products.

The minerals estimated in the raw materials and extruded snack are shown in Table 2. From the data it is observed that buckwheat flour contains good amount of both macro and micro-minerals. The detected values for Mg, K, Ca, Fe, Zn, Mn and Cu were 220 ± 4.0 mg/100 g, 392 ± 8.0 mg/100 g, 40 ± 6.0 mg/100 g, 6.8 ± 0.6 mg/100 g, 3.5 ± 2.0 mg/100 g, 1.5 ± 0.5 mg/100 g and 0.8 ± 0.0 mg/100 g respectively. Our results are within the range of earlier reports on milling fractions (Ikeda et al. 1994; Steadman et al. 2001; Skrabanja et al. 2004) and buckwheat based bread (Krupa-Kozak and Wronkowska 2011) and biscuit (Filipcev et al. 2011).

It is observed from our study that utilisation of buckwheat can increase the nutrient content of the product. The extruded snack showed appreciable amount of macro-minerals namely Mg (169 ± 1.0 mg/100 g), K (373 ± 9.0 mg/100 g) and Ca (46 ± 0 mg/100 g). Fe and Zn in particular were present in high amount with detected values of 4.5 ± 1.6 mg/100 g and 3.46 ± 1.0 mg/100 g respectively. The extruded snack also contain Mn (1.1 ± 0.2 mg/100 g) and Cu (0.5 ± 0.0 mg/100 g).

Conclusion

Desirable physical and sensory attributes are vital parameters for consumer acceptability in ready-to-eat snacks. The present study addresses alternative use of bread wastes from bakery industry in producing snacks of desirable organoleptic qualities. The studies show that upto 40% bread powder can be utilized in producing low-fat nutritious snack. It also widens the use of underutilized nutrient-dense pseudo-cereal such as buckwheat. The developed ready-to-eat extruded baked snack has significant amount of dietary fiber (7.45 ± 2.54), protein (15.33 ± 2.56) and important minerals namely iron (4.5 ± 1.6 mg/100 g) and zinc (3.46 ± 1.0 mg/100 g). The study also provided the scope for further work on re-use of other forms of bakery waste in different food products.

Funding

This work was supported by the Department of Science and Technology- Science and Engineering Board (DST-SERB), Government of India.

Compliance with ethical standards

Conflict of interest

The authors declare that there is no conflict of interest.

Human and animal rights statement

This study does not involve any human or animal testing.

Informed consent

All the authors agree to submit this manuscript.

Footnotes

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

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