RESUMEN
BACKGROUND: Three-dimensional (3D) food printing is a promising method for developing nutritious snack foods with complex and customized structures. In this study, to develop a pearl millet-based snack formulation, the printability of pearl millet flour (PMF) was assessed, without and with the addition of banana pulp (BP), a natural taste and flavor enhancer, at five different levels (PMF:BP of 100:0, 80:20, 60:40, 40:60, 20:80 and 0:100). RESULTS: The water activity significantly decreased with increases in the proportion of BP; higher water activity was exhibited at 100:0 (0.99). The BP proportion influences all the color values (redness: 2-11; yellowness: 17-31.87; total color difference: 2-17). All formulations exhibited shear-thinning behavior (n = 0.02-0.49) and higher hardness (0.2-0.4 N), but not all were printable. A significant decrease in adhesiveness (-0.2 to -0.03 N s) and higher storage modulus (2000-6000 Pa) occurred with an increased proportion of BP. Findings from detailed rheological behavior assessment (static, dynamic and three-interval thixotropy tests) better correlated with trends observed during 3D extrusion printing. The highest yield stress was attained (80 Pa) in the 100:0 formulation. From the thixotropy test, more deformation (>80%) and recovery (>100%) were attained by three of the formulations (100:0, 80:20, 60:40). Overall, the best constructs were obtained (based on the visual sensory characteristics) for the 60:40 formulation printed at 600 mm min-1 printing speed and 240 rpm extrusion motor speed through a 1.22 mm nozzle. CONCLUSION: The findings of this work will provide valuable insights into the development of novel millet-based 3D printed foods. © 2024 Society of Chemical Industry.