Influences of modified fiber inclusion with varying particle size on corn starch‐based extrudate expansion

Abstract The inclusion of cellulose nanocrystals (CNC) and microcrystalline cellulose (MCC) during extrusion processing of corn starch (CS) is presented in this study. Blends were prepared by incorporating CNC and MCC at different concentrations, 1%, 3%, 5%, and 10% w/w in CS. The crystallinity index (CrI) of CNC and MCC was determined using X‐ray diffraction, and the chemical functionality of CNC, MCC, and CS was studied using Fourier transform infrared spectroscopy. The pasting properties of the blends were studied using Micro Visco‐Amylo‐Graph before extrusion. The blends were preconditioned to 18 ± 0.5% (w.b.) moisture and extruded using a twin‐screw extruder at 200 and 250 rpm at 140°C. CS‐CNC's expansion ratio (ER) values were 2.95 to 3.35 and 2.72 to 3.22 for MCC. CNC's CrI and particle size were significantly lower than MCC, allowing CNC‐based extrudates to have ER values similar to the control even at high CNC concentration (≤10% w/w). This study demonstrated that fiber with particle size <100 µm can be added in direct‐expanded product formulations at high concentrations without negatively influencing the extrudate texture while offering increased nutritional value. Practical Application This study gives insight into the potential application of cellulose nanocrystals and microcrystalline cellulose in manufacturing direct‐expanded extruded products, providing high fiber content without compromising the product quality. This knowledge could also be translated into manufacturing other food products such as breakfast cereals, pasta, and bread.