Extrusion of process flavorings from methionine and dextrose using modified starch as a carrier.

This study aimed to produce process flavorings from methionine and glucose via Maillard reaction by extrusion method. Modified starch was used as a carrier to reduce the torque and facilitate the production process. Five formulations of process flavorings with different ratios of methionine: dextrose: modified starch: water as MS5 (72:18:5:5), MS15 (64:16:15:5), MS25 (56:14:25:5), MS35 (42:12:35:5), and MS45 (40:10:45:5) were prepared and feded into the extruder. The temperatures of the extruder barrel in zones 1 and 2 were controlled at 100, and 120°C, with a screw speed of 30 rpm. The appearance of the obtained products, torque, pH before and after extrusion, color, volatile compounds, and sensory evaluation were determined. The extrudate from the formulation containing the highest amount of modified starch (MS45) gave the highest L* (lightness) of 88.00, which increased to 93.00 (very light) after grinding into a powder. The process flavorings from all formulations exhibited similar sensory scores in terms of aroma, taste, and water solubility, with a very slight difference in color. However, MS25, MS35 and MS45 indicated the torque at 10 Nm/cm3, while MS5 and MS 15 exhibited higher torque at 18, and 25 Nm/cm3, respectively. Extruded process flavorings from MS25 were analyzed for their flavor profiles by gas chromatography-mass spectrometry. Twelve volatile compounds including the key volatile compounds for sulfurous and vegetable odor type, dimethyl disulfide, methional, and methanethiol, were found. Four pyrazine compounds presented nutty, musty and caramelly odor; and 3-hydroxybutan-2-one and heptane-2,3-dione, which gave buttery odor type, were also detected. The results demonstrated a successful production of process flavorings using modified starch as carrier to facilitate and reduce the torque during the extrusion process.

Production of process flavorings from methionine, thiamine with d-xylose or dextrose by direct extrusion: Physical properties and volatile profiles.

The conventional method to produce process flavoring is non-continuous, time consuming, and generates a high volume of effluent. This research aimed to evaluate the use of methionine, thiamine, and reducing sugars to develop process flavorings by direct extrusion, as a potential alternative to the conventional method. The mixed substrates consisted of methionine: d-xylose (MX), methionine: dextrose (MD), thiamine: d-xylose (TX), and thiamine: dextrose (TD) at 80:20 w/w. Three barrel temperatures of the extruder were controlled at 65, 80, and 50°C, respectively, a screw speed of 30 rpm and feed rate at 3 kg/hr. Appearance, pH, odor, and taste description of the product from each mixture were determined. Volatile compounds, possibly occurred from the Maillard reaction during the extrusion were analyzed by gas chromatography-mass spectrometry. The products exhibited different levels of meaty odor and bitter taste. Those obtained from MD showed the highest L* (lightness, 85.37) and frequency for just-about-right in terms of taste (33.33%) and odor (60.00%). Products from MX and MD presented the highest frequency for intense taste, and higher frequency for color compared to TX and TD. More volatile compounds were detected from the use of methionine than from thiamine. The key meaty odor compounds such as dimethyl disulfide, dimethyl trisulfide, methional, and methanethiol were found in the samples from MX and MD, while only dimethyl disulfide was detected in the mixture of TX and TD. Finally, the results demonstrated that direct extrusion reaction from methionine and d-xylose or dextrose is a highly efficient method to produce meaty process flavorings. PRACTICAL APPLICATION: The manuscript describes the production of process flavorings that exhibited meaty flavors by extrusion process. Physical properties, volatile profiles, and sensory evaluation of the products from methionine, thiamine, d-xylose, and glucose were evaluated. The extruded products from methionine and dextrose exhibited acceptable color, taste, and odor and presented many volatiles compounds contributing to meaty flavors. The results revealed the high potential to use a direct extrusion process with very low effluent, compared to the conventional method, to produce meaty flavors for industrial application.