Corn meal of various particle sizes ranging from 180 to 710 lm were processed in a twin-screw extruder to produce directly expanded extrudates. The extrusion process effects on the specific mechanical energy (SME), expansion indexes (radial, longitudinal and volumetric), pasting viscosity, water absorption index (WAI) texture properties, and microstructure were determined. Increasing the particle size decreased the SME input. Extrudates produced with corn meal of higher particle sizes expanded more than extrudates produced with smaller particle sizes. For all treatments there was no peak viscosity at 95 C. But expanded corn meal extrudate from the 180 lm fraction showed a discontinuous gel matrix phase. Increasing corn meal particle size decreased WAI values. The mechanical resistance of the extrudates from the smallest particle size was significantly higher (p < 0.05) than that of the largest particle size. The microstructure of raw corn meal revealed large fractured particles with small rounded particles adhering to the surface.
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