Type | Snack food |
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Place of origin | United States |
Main ingredients | Cornmeal, flavoring |
Puffcorn or corn puffs are puffed or extruded corn snacks made with corn meal, which can be baked or fried.
Puffcorn belongs in the snack group products made with corn grits, rice, wheat, or other cereals. Puffcorn is often flavoured with cheese, caramel, oil, chili, onion, or garlic powder, and many other spices. [1] Types of puffcorn can vary in length, density, hardness, springiness, gumminess, chewiness, and level of redness and yellowness, especially when using different percentages of oat flour. [2] Some products sold as puffcorn are given the appearance of popcorn, although they are not made from whole grains as popcorn is.
Puffcorn is commonly known as a ready‐to‐eat functional breakfast cereal or an extruded functional snack. [2] Some puffcorn is made with oat flour, flaxseed and chia corn. [2] Due to the health benefits, there has been increased interest in developing functional food products containing chia. [3] Extrusion has been shown to be an effective method for incorporating other functional ingredients into food products. [4]
Manufacturers include Frito-Lay, [5] and Old Dutch Foods. [6]
Sweetened (Corn Pops, Reese's Puffs, etc.) and salty/seasoned (Kurkure, various cheese puffs, etc.) varieties also exist.
Puffcorn, much like other puffed products such as cereals and crispbreads are processed by extrusion cooking through an extruder. This is a thermodynamic process where the dough is passed through a tube and heated under a certain amount of pressure. The puffcorn dough product is then forced through a narrow opening called a die, and as it gets released, the change in pressure and temperature causes the product to puff out, giving the texture and consistency of puffcorn. [7] [ self-published source ] The different shapes and textures of puffcorn are manipulated by the die at the end of the extruder and the type of extruder used. Specific types of grain size of the starch required during processing also depends on the snack type itself; for example, if the puffcorn snack requires a fine structure with small pores, an extruder with smaller granulation should be used, whereas crispier puffcorn would require larger granulation. [8]
Factors that are considered to determine the packaging material of extruded snacks like puffcorn are water vapour transmission rate (WVTR), oxygen transmission rate (OTR), optical density (OD), and flavour/odor barrier property. The packaging of choice ultimately compromises between protective properties, the shelf life of the product, aesthetic appeal, and cost. [9] Given that deterioration of puffcorn products is primarily attributed to loss of crispness, it is crucial that the packaging provides a barrier against water vapour. Oxygen barrier requirements for the packaging of puffcorn may be less stringent as extruded and puffed snacks can be less sensitive to oxygen in comparison with fried snack foods. [10] A variety of materials can be used in packaging of puffcorn, examples of which include low-density polyethylene (LDPE), laminated pouches (LP), and biaxially-oriented polypropylene (OPP). In an investigation, extruded snacks were found to be more stable in LP in comparison to LDPE. [11]
Starch, the main constituent of puffcorn, is accountable for the snack's structural properties, and thus expires in 3–4 months. [12] During the extrusion process, starch molecules (amylose) are destroyed partially while new crystalline ones are made. They form an amylose-lipid complex affecting puffcorn's structure, texture and other functional properties. [13] Due to the moist heat, the extrusion process may also cause starch gelatinization, protein denaturation, destruction of microorganisms and inactivation of anti-nutrients. [14] Compared to wheat, using corn results in a softer and more expanded product due to its lower protein content and higher starch content (extruded wheat products are harder and don't expand as much). [12]
The quality and overall acceptability of puffcorn, as determined by consumers, is based on characteristics pertaining to their appearance, texture, and flavour (determined via sensory evaluation methods). [15] Desired sensory attributes are attained by controlling the composition of the raw material and the processing conditions during extrusion.
Characteristics of puffcorn, notably diameter, porosity, and homogeneous structure, are appearance attributes that aid in the perception of quality of the extruded product. [15] The appearance of these products are enhanced as extrusion feed rate is increased, while increases in extrusion temperature and feed moisture content diminish it. Colour changes during extrusion occur due to product expansion, the decomposition of ingredient pigments, or chemical reactions.
Textural attributes of these extrudates are often associated with their mechanical behaviour, and are related to their appearance and flavour properties. [15] Crispness and melting of extrudates are influenced by extrusion temperature. Higher extrusion temperatures enhance the crispness and melting of extrudates. Feed moisture content decreases the crunchiness and crispness while increasing hardness (density) of the product. Hardness increases the perceived mealy flavour, and is negatively correlated with crispness, melting and burnt flavouring.
Starch or amylum is a polymeric carbohydrate consisting of numerous glucose units joined by glycosidic bonds. This polysaccharide is produced by most green plants for energy storage. Worldwide, it is the most common carbohydrate in human diets, and is contained in large amounts in staple foods such as wheat, potatoes, maize (corn), rice, and cassava (manioc).
Tapioca is a starch extracted from the tubers of the cassava plant, a species native to the North and Northeast regions of Brazil, but whose use is now spread throughout South America. It is a perennial shrub adapted to the hot conditions of tropical lowlands. Cassava copes better with poor soils than many other food plants.
Marshmallow is a confectionery made from sugar, water and gelatin whipped to a solid-but-soft consistency. It is used as a filling in baking or molded into shapes and coated with corn starch. This sugar confection is inspired by a medicinal confection made from Althaea officinalis, the marsh-mallow plant.
Mochi is a Japanese rice cake made of mochigome (もち米), a short-grain japonica glutinous rice, and sometimes other ingredients such as water, sugar, and cornstarch. The steamed rice is pounded into paste and molded into the desired shape. In Japan, it is traditionally made in a ceremony called mochitsuki. While eaten year-round, mochi is a traditional food for the Japanese New Year, and is commonly sold and eaten during that time.
Cornflour, cornstarch, maize starch, or corn starch is the starch derived from corn (maize) grain. The starch is obtained from the endosperm of the kernel. Corn starch is a common food ingredient, often used to thicken sauces or soups, and to make corn syrup and other sugars. Corn starch is versatile, easily modified, and finds many uses in industry such as adhesives, in paper products, as an anti-sticking agent, and textile manufacturing. It has medical uses as well, such as to supply glucose for people with glycogen storage disease.
Amylose is a polysaccharide made of α-D-glucose units, bonded to each other through α(1→4) glycosidic bonds. It is one of the two components of starch, making up approximately 20–30%. Because of its tightly packed helical structure, amylose is more resistant to digestion than other starch molecules and is therefore an important form of resistant starch.
Amylopectin is a water-insoluble polysaccharide and highly branched polymer of α-glucose units found in plants. It is one of the two components of starch, the other being amylose.
Extrusion is a process used to create objects of a fixed cross-sectional profile by pushing material through a die of the desired cross-section. Its two main advantages over other manufacturing processes are its ability to create very complex cross-sections; and to work materials that are brittle, because the material encounters only compressive and shear stresses. It also creates excellent surface finish and gives considerable freedom of form in the design process.
Kix is an American brand of breakfast cereal introduced in 1937 by the General Mills company of Golden Valley, Minnesota. The product is an extruded, expanded puffed-grain cereal made with cornmeal.
Old Dutch Foods, Inc. is a manufacturer of potato chips and other snack foods in the Midwestern United States, New England and Canada. Their product line includes brands such as Old Dutch Potato Chips, Dutch Crunch, Ripples, Cheese Pleesers and Restaurante Style Tortilla Chips.
Cheese puffs, cheese curls, cheese balls, cheese ball puffs, cheesy puffs, or corn curls are a puffed corn snack, coated with a mixture of cheese or cheese-flavored powders. They are manufactured by extruding heated corn dough through a die that forms the particular shape. They may be ball-shaped, curly, straight, or irregularly shaped. Puffcorn is a similar food, without cheese flavoring.
Puffed grains are grains that have been expanded ("puffed") through processing. They have been made for centuries with the simplest methods like popping popcorn. Modern puffed grains are often created using high temperature, pressure, or extrusion.
The Smith's Snackfood Company is a British-Australian snack food brand owned by the American multinational food, snack, and beverage corporation PepsiCo. It is best known for its brand of potato crisps. The company was founded by Frank Smith and Jim Viney in the United Kingdom in 1920 as Smiths Potato Crisps Ltd, originally packaging a twist of salt with its crisps in greaseproof paper bags which were sold around London. The dominant brand in the UK until the 1960s when Golden Wonder took over with Cheese & Onion, Smith's countered by creating Salt & Vinegar flavour which was launched nationally in 1967.
Puffed rice and popped rice are types of puffed grain made from rice commonly eaten in the traditional cuisines of Southeast Asia, East Asia, and South Asia. It has also been produced commercially in the West since 1904 and is popular in breakfast cereals and other snack foods.
Resistant starch (RS) is starch, including its degradation products, that escapes from digestion in the small intestine of healthy individuals. Resistant starch occurs naturally in foods, but it can also be added as part of dried raw foods, or used as an additive in manufactured foods.
Corn snacks are snack foods made from corn (maize). They are often marketed, packaged and flavoured in a similar way to potato crisps.
Mouthfeel refers to the physical sensations in the mouth caused by food or drink, making it distinct from taste. It is a fundamental sensory attribute which, along with taste and smell, determines the overall flavor of a food item. Mouthfeel is also sometimes referred to as texture.
Extrusion in food processing consists of forcing soft mixed ingredients through an opening in a perforated plate or die designed to produce the required shape. The extruded food is then cut to a specific size by blades. The machine which forces the mix through the die is an extruder, and the mix is known as the extrudate. The extruder is typically a large, rotating screw tightly fitting within a stationary barrel, at the end of which is the die.
Mian Nadeem Riaz is a Pakistani–American food scientist, academic and author. He is a professor in food diversity, director of the Extrusion Technology Program and the Associate Department head of the Food Science and Technology Department at Texas A&M University.