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Use of Partially Defatted Peanut Flour in Breakfast Cereal Flakes

Article  in  Cereal Chemistry · July 2002

DOI: 10.1094/CCHEM.2002.79.4.586

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 Use of Partially Defatted Peanut Flour in Breakfast Cereal Flakes

P. Cheewapramong,1,2 M. N. Riaz,3 L. W. Rooney,4 and E. W. Lusas5

ABSTRACT Cereal Chem. 79(4):586–592

Extruded breakfast cereal flakes were made by replacing corn cones color, bowl life, water absorption, and water solubility indices were
with nonroasted partially defatted peanut flour (PDPF) and roasted significantly affected by the amount of PDPF and R-PDPF added in the
partially defatted peanut flour (R-PDPF) at various levels (10, 20, and formulation. A sensory panel found extruded toasted flakes made from
30%). The mixtures were extruded using a corotating twin-screw extruder corn cones and up to 20% R-PDPF were acceptable as control. Peanut
to produce collets. The collets were flaked and then toasted. The extruded flavor intensity was also evaluated. Surprisingly, peanut flavor intensity was
toasted flakes were analyzed for physical, physicochemical, and sensory the highest for flakes containing 30% PDPF, rather than those containing
characteristics. Moisture content, bulk density, hardness (force to break), 30%R-PDPF.

Extrusion is one of many techniques used for manufacturing flavor of partially defatted peanut flour and alter the physical
ready-to-eat (RTE) cereals (Harper 1981). Midden (1989) and Bailey properties of products in which it is incorporated. Therefore, the
(1991) produced breakfast cereal flakes using a twin-screw extruder. purpose of this study was to evaluate the effects of partial replace-
The extrusion process reportedly has numerous processing conveni- ment of roasted and nonroasted peanut flours for corn cones to
ences over conventional processing methods, including faster pro- produce breakfast cereal cornflakes, and also to determine the maxi-
cessing, lower processing cost, and lower space cost. Four factors mum amount of peanut flour that can be substituted to produce
that should be monitored in extrusion processing are temperature, acceptable high-protein flakes.
cooking time, moisture, and shear (Miller 1994). Overly sheared
products absorb moisture quickly and become soggy. They can have MATERIALS AND METHODS
a slimy mouthfeel or odd flavors. Rokey (1995) stated that longer
cooking time, higher moisture, moderate temperature, and minimum Raw Materials
shear are the most important factors in cornflakes acceptability. Peanuts (Arachis hypogaea L. cv Spanish) were obtained from
Generally, peanuts are considered as an oilseed crop grown pri- the Birdsong Peanut Corp. (Gorman, TX). Sunlite yellow corn cones
marily for oil production. A high-protein peanut press cake, which is (#S 40) were obtained from the J. R. Short Milling Co. (Kankakee,
normally used for animal feed, is a byproduct derived from the oil IL); the particle size specification is shown in Table I. Malt (Malto-
extraction process. Peanut press cake, however, can be used for line ER Light) was purchased from Crompton & Knowles Corp.
human food if it is processed from food-grade peanuts under hy- (Mahwah, NJ). Yellow corn meal (ConAgra Inc., Omaha, NE), white
gienic environments (Lusas 1979). Peanut flour has a relatively high sugar (Domino Sugar Corp., NY), and iodized salt (Morton Inter-
protein content, bland flavor, and light tan color which allow it to be national, Inc., Chicago, IL) were purchased from a local supermarket.
incorporated into a wide range of foods (Prinyawiwatkul et al 1995).
The use of peanut flour as a protein supplement in breakfast cereals Preparation of Roasted and Nonroasted Partially Defatted
has been extensively studied. Spadaro et al (1971) used rice grits Peanut Flours
mixed with defatted peanut flour to make products with higher protein Peanuts were blanched in batches of 2.3 kg for 30 sec using a
content and desirable cereal-like flavor. Harris et al (1972) devel- mini-dehuller (Nutana Machine, Saskatoon, Canada) to remove skins.
oped breakfast cereal flakes that compared favorably with com- Oil was removed using a dry extruder (InstaPro International, Des
mercial flakes by drum-rolling dough mixtures of defatted peanut, Moines, IA) and a continuous horizontal screw press (InstaPro 1500).
corn, and wheat flour. Extrusion of peanut flour with corn and oats Peanut press cakes were divided into two lots. One lot of press
produced breakfast cereals with high protein content, but these cakes was roasted in a hot air oven (Despatch Ovens Co., Minne-
products absented peanut flavor (Ayres and Davenport 1977). Suknark apolis, MN) at 166°C for 8 min, and immediately cooled to room
et al (1997) recently investigated physical properties of directly ex- temperature. The other lot was not roasted. The roasted and non-
panded extrudates by blending partially defatted peanut flour with roasted press cakes were milled (Bauer Bros Co., Springfield, OH)
different types of starch using single-screw extruder at different con- and then sieved through a 60-mesh screen. The partially defatted
ditions. peanut flours were stored at 3°C until used for further product devel-
A peanut flour with very low fat content and strong roasted peanut opment and analyses.
flavor has only limited application in the food industry, especially
in breakfast cereal flakes. A definite need exists for a strongly flavored Flakes Formulation
partially defatted peanut flour for use in reduced-fat food products. The base formula used for making flakes is shown in Table II. The
In an attempt to produce peanut-flavored flakes, corn cones were control formula had only corn cones. In the test formula, corn
also mixed with roasted peanut flour. Roasting process may improve cones were replaced by PDPF and R-PDPF at levels of 10, 20, and
30% of the total mix. All blends contained 10% sugar, 3% malt, and
2% salt. To improve texture, mouthfeel, blistering, and appearance of
1 Graduate student, Dept. of Food Science & Technology, University of Nebraska- the final flakes, corn meal (8.5%) was added to the cornflakes formula
Lincoln, NE 68583-0919. as suggested by E. Sevatson (Wenger Mfg. Co., personal commun-
2 Corresponding author. E-mail: [email protected]. Phone: (402) 472- ication).
2912. Fax: (402) 472-1693.
3 Graduate Faculty, Food Protein R&D Center, Dept. of Soil & Crop Sciences, Texas The process used to produce flaked cereal is shown in Fig. 1.
A&M University. Each blend (13 kg) of dry ingredients was mixed in a dry vertical
4 Professor, Cereal Quality Laboratory, Dept. of Soil & Crop Sciences, Texas mixer (Hobart Mfg., Troy, OH) at low speed for 2 min. Liquid
A&M University. malt was added gradually to dry ingredients and mixed for 5 min at
5 Consultant, Problem Solvers Inc, (PSI) 3604 Old Oaks Dr., Bryan, TX 77802.
medium speed. Mixing continued at low speed for 20 min to ensure
Publication no. C-2002-0611-02R. homogeneity. All blends were held in tied plastic bags overnight at
© 2002 American Association of Cereal Chemists, Inc. 3°C. Before extrusion, the mixes were brought to room temperature.
586 CEREAL CHEMISTRY
Extrusion Process Flaking and Toasting Process
A corotating, intermeshing, twin-screw extruder (TX-52, Wenger Flaking and toasting were conducted at the Wenger Mfg. pilot
Mfg. Co., Sabetha, KS) equipped with a 25.5:1 (nine heads) length-to- plant in Sabetha, KS. Collets were flaked using Wenger RS-90 faking
diameter ratio extruder barrel was used. A vent was used on the 7th rolls. The flaking rolls were operated at constant speed (1,135 ft/min).
head to depressurize steam to the atmosphere. Chilled water (9°C) The gap between the rolls was 0.43 mm. The flakes were toasted
was circulated in the barrel in zones 5 and 6 (8th and 9th heads) to in a Wenger 4800 drier/toaster at 170°C for 3 min. Dried flakes were
avoid puffing of the collets. The feeder, preconditioner, and main stored in plastic bags at room temperature for other measurements.
twin-screws were operated at 13, 96, and 165 rpm, respectively.
Material flow rate was held at 64 kg/hr. In the preconditioner, steam Experimental Design
was added at a rate of 0.3 kg/min, and water at a rate of 0.112 kg/min. The research design included seven trials, one control, peanut flour
Retention time in the preconditioner was 240 sec. The exiting tem- and corn cones at ratios of 10:90, 20:80, and 30:70, and two types
perature of product from the preconditioner was 91°C. Temperatures (roasted and nonroasted) of partially defatted peanut flour. Each
of zones 1 through 6 of the extruder barrel were held constantly at trial was performed in triplicate. The run order of all blends was ran-
60, 100, 100, 90, 60 and 60°C, respectively. The head pressure was domized. Twenty-one extrusion trials were completed in one day.
 425 PSI. Steam was injected into the extruder barrel at a rate of
Measurement of Physicochemical Properties
0.08 kg/min. No water was added at the extruder barrel. A die with
The raw material and extruded flakes were ground in the CRC
four inserts (6-mm round holes) was used. The temperature of collets
micromill (The Chemical Rubber Co., Cleveland, OH) to pass through
exiting from the extruder was  98°C.
a 60-mesh sieve for analyses. Proximate analyses were performed
Extrusion was allowed to reach the steady state for at least 5 min
using official procedures (AOAC 1993), with the exception of protein
between trials, and then collets were collected. The round-shaped
analysis. Crude protein was determined by the Kjeldahl method
collets were later cooled in trays at room temperature. Collet size from
(AOAC 1990).
each trials was similar at  36 beads/100 gm. An effort was made
Bulk density was analyzed for all extruded toasted flakes in tripli-
to collect these collets in one layer to keep them separated. Collets
cate using the Winchester bushel meter (Seedburo Equipment Co.,
were held in air-tight plastic bags for two days at cold storage (3°C) to
Chicago, IL). Samples were filled to overflowing in the measuring
allow moisture equilibration. Then they were delivered for flaking.
cylinder (35.24 L) without tapping, then leveled off with a straight-
edge, and weighed (calculated wt. of sample/unit volume [g/L]).
Hardness (force-to-break) was determined on 10 extruded toasted
flakes from each extrusion run using the texture analyzer (TA.XT2,
Texture Technologies Corp., Scarsdale, NY) with the small probe
(TA-52). The compression test mode was used. The parameters were
pretest speed 5 mm/sec, test speed 1 mm/sec, and distance 5 .0 mm.
Color difference measurements (L, a, and b) were made in tripli-
cate on the extruded toasted flakes using Hunterlab tristimulus colori-
meter (Reston, VA). Flakes (7 g) were broken into small pieces and
arranged to cover the bottom of a sample cup.
Water absorption (WAI) and water solubility (WSI) indices were
determined in triplicate followed the procedure of Anderson et al
(1969). WAI is the weight of the gel obtained per gram of dry sample.
WSI is the amount of solids recovered by evaporating the super-
natant from the water absorption tests, expressed as percentages of
dry solids in the sample.
The time (min) for crispness to disappear was recorded as the
“bowl life”. The disappearance of crispness was determined subjec-
tively by soaking 10 g of samples in cold milk (10°C) and chewing
flakes at 1-min intervals until crispness disappeared (Celis et al 1996).
The measurements were evaluated in triplicate. Three different (A, B,
and C) commercial cornflake products were purchased from local
stores and also tested. Commercial cornflakes A and B are processed

TABLE I
Typical Particle Size Specification of Corn Conesa
Granulation Specification
2Q861R6LHYH P 0
6LHYH P 2% max.
6LHYH P 95% min.
Thru 80 4% max.
a Data provided by J.R. Short Milling Co., Kankakee, IL.

TABLE II
Breakfast Cereal Flakes Formulationa
Ingredients Percent
Corn cones 76.50
Corn meal 8.50
White sugar 9.96
Malt 3.08
Salt 1.96
a Excludes roasted and nonroasted partially defatted peanut flour variables.
Fig. 1. Processing scheme for extruded breakfast cereal flakes.

Vol. 79, No. 4, 2002 587

by a traditional method that uses whole or parts of grains cooked protein, oil, and fiber contents than corn cones. The protein content
in batch cookers and takes 8 hr or more to be accomplished. of peanut flours had high protein (46.8% db), fat (7.8% db), and
Commercial cornflakes C are produced by extrusion technique. fiber (3.7% db) content compared with corn cones. Roasting reduced
the moisture content of partially defatted peanut flour but did not
Amino Acid Analysis otherwise affect the composition.
All amino acids, except for tryptophan, cysteine, and proline, were WAI and WSI of peanut flours were higher than those of corn
determined by a fluorometric HPLC method using precolumn deriva- cones (Table IV). This can be explained by the fact that peanut flour
tization with o-phthaldialdehyde according to the procedure of Wu has a higher protein content resulting in more hydrophilic groups that
and Knabe (1994). Corn cones (2.0 g) and partially defatted peanut could bind more water molecules than corn cones. Additionally, par-
flour (0.2 g) were hydrolyzed in 250 mL of 6N HCl. The solutions ticle size of peanut flour was finer than that of corn cones, resulting
were incubated at 110°C under nitrogen for 24 hr. The protein in higher WSI. Roasting significantly increased the WAI of partially
hydrolysate was analyzed for amino acids. defatted peanut flour; in contrast, it decreased the WSI of the flour.
The effect of roasting on WAI and WSI of PDPF was similar to that
Sensory Evaluation
reported by Singh and Singh (1991). The yellow color, as indicated
Flakes (10 g) containing 0, 10, 20, and 30% R-PDPF and 30%
by b value, was higher in corn cones, and apparently was caused by
PDPF were evaluated by 48 untrained panelists. Flakes containing 10
carotenoid pigments, carotenes, and xanthophylls (Weber 1987).
and 20% PDPF were not evaluated because the purpose of this
Roasting reduced lightness and increased the red and yellow hues.
study was to improve the flavor of roasted peanut; only the 30%
Roasting also caused hydrolysis of sucrose to glucose and fructose.
PDPF sample was evaluated. Additionally, too many samples will
Then, these reducing sugars reacted with amino acids to produce
make panelists more tired and confused. Texture (crispness), color,
melanoidin pigments by the Maillard reaction, also perhaps due to
flavor, and overall acceptability, were evaluated using a nine-point
caramelization reactions (Whistler and Daniel 1985).
hedonic scale (1 = dislike extremely, 9 = like extremely) at 1 min
after addition of milk as desired. Intensity of peanut flavor also was
Amino Acid Analysis
evaluated using a nine-point scale (1 =none, 9 = strong). The sen-
Higher amounts of almost all essential amino acids, especially
sory evaluations were conducted in a single session. Samples were
lysine, occurred in PDPF than in corn cones (Table V). However,
coded with three-digit numbers to avoid influencing panelist deci-
PDPF contained lower amounts of methionine and histidine. In
sions. The samples were presented one at a time in randomized order.
general, most cereals are lower in total protein content and deficient in
Panelists were supplied with deionized distilled water ( 25°C) for
lysine for optimal nutritional quality. The available lysine content
rinsing between samples.
of peanuts is high compared with levels found in cereals (Johri et al
Statistical Analysis 1988). The protein quality of corn meal is substantially improved by
The treatment means were analyzed by the general linear models fortification with peanut flour (Bookwalter et al 1978).
procedure using the SAS statistical software package (v. 6.09, SAS
Institute, Cary, NC). Duncan’s multiple range test was used for Moisture Content
multiple means comparison. Moisture content in each step of extruded flakes production were
recorded (Table VI). These include the mixes before precondi-
RESULTS AND DISCUSSION tioning and at entering the extruder, collets, and toasted flakes.
Moisture contents decreased with the amount of peanut flour added.
The proximate composition of peanut flours, corn cones, and corn Product moisture contents correlated with initial feed moisture
meal are given in Table III. Partially defatted peanut flour had higher contents and were thus lowest for the toasted flakes containing

TABLE III
Proximate Composition (%) of Raw Materials Used for Breakfast Cereal Flakesa
Samples Moisture Proteinb Oil Ash Fiberc Carbohydrated
Corn cones 13.71 ± 0.08 6.34 ± 0.03 1.09 ± 0.09 0.33 ± 0.03 0.55 ± 0.07 77.98 ± 0.11
Corn meal 13.21 ± 0.12 7.03 ± 0.02 1.63 ± 0.07 0.64 ± 0.04 0.85 ± 0.07 76.64 ± 0.22
PDPFe 6.13 ± 0.14 43.93 ± 0.06 7.28 ± 0.17 4.04 ± 0.03 3.45 ± 0.07 35.17 ± 0.07
R-PDPFf 4.06 ± 0.34 44.88 ± 0.06 7.46 ± 0.16 4.12 ± 0.05 3.57 ± 0.06 35.91 ± 0.53
a Values are means ± standard deviation of triplicate determinations (% as is basis).
b N ™ 6.25 (corn), N ™ 5.46 (peanut).
c Crude fiber, determined by Mid-Continent Laboratories, Memphis, TN.
d Determined by difference.
e Nonroasted partially defatted peanut flour.
f Roasted partially defatted peanut flour.

TABLE IV
Physical and Physicochemical Properties of Raw Materials Used for Preparation of Flakesa
Colorb
Samples WAIc (g/g) WSId (g/100 g) L a b
Corn cones 2.19 ± 0.02h 2.10 ± 0.02h 81.6 ± 0.1f 2.1 ± 0.1g 34.2 ± 0.2f
PDPFe 2.33 ± 0.06g 43.10 ± 0.45f 76.0 ± 0.3g 1.2 ± 0.1h 13.0 ± 0.1h
R-PDPFf 2.59 ± 0.09f 38.30 ± 0.80g 74.5 ± 0.3h 2.3 ± 0.1f 17.1 ± 0.2g
a Values are means ± standard deviations of triplicate runs. Values followed by the same letter in the same column are not significantly different (P < 0.05)
using Duncan’s multiple range test.
b L = brightness (0 = black, 100 = white); +a = red, –a = green; +b = yellow, –b = blue.
c Water absorption index is the weight of the gel obtained per gram of dry sample.
d Water solubility index is the amount of solids recovered by evaporating supernatant from water absorption tests, expressed as % of dry solids in sample.
e Nonroasted partially defatted peanut flour blended by weight with corn cones.
f Roasted partially defatted peanut flour blended by weight with corn cones.

588 CEREAL CHEMISTRY

30% peanut flours. Additionally, increasing oil contents may also resulting in lower densities. Lowering moisture content of raw
affect the decrease of final moisture of the products. Mohamed material mixture by substitution of peanut flours tended to reduce
(1990) reported the addition of oil up to 3% decreased the product the bulk density of the flakes. Similar investigations were reported
moisture content. This probably caused by increasing the efficiency of by Camire (1989) and Suknark et al (1997). They noted that as feed
heat transfer. moisture increased, bulk density of the extrudates also increased.

Composition of Flakes Hardness

The addition peanut flour increased the protein content from 6.7% The greatest force was needed to compress control extruded
in control flakes (no peanut flour added) to 16.6 and 16.9% in flakes toasted flakes (Table VIII). PDPF and R-PDPF reduced hardness
containing 30% PDPF and 30% R-PDPF, respectively (Table VII). of extruded toasted flakes. There were no differences according to
The oil content of the flakes was 0.93–2.43% and was highest in the type of PDPF used (P > 0.05). Products with high bulk density
flakes containing 30% peanut flour. The crude fiber content was generally require more force to break as reported by Bhattacharya
slightly increased by the addition of peanut flour. Flakes with higher et al (1986) and Prinyawiwatkul et al (1995); thus, extruded toasted
fiber contents can be associated with important health benefits, in- flakes with high bulk density would be harder. In the present
cluding maintenance of gastrointestinal function plus lowering of work, a positive correlation was found between hardness and bulk
serum cholesterol levels. density (r = 0.86). Higher lipid levels can reduce forces for
breaking and shearing the product (Bhattacharya et al 1986). The
Bulk Density same results were also reported by Suknark et al (1997). They
The addition of PDPF and R-PDPF lowered bulk densities of found that the substitution of PDPF for starch at low levels (15–30%)
extruded toasted flakes (Table VIII). The type of peanut flour did decreased the shear strength. Conversely, shear strength increased as
not significantly affect the bulk density of extruded toasted flakes. the level of PDPF in the mixture further increased. This can be
Similar observations were reported by other researchers. Hagen et explained as the small amount of lipid in peanut increasing the expan-
al (1986) observed the microstructure of textured peanut concentrate sion, resulting in thinner cell walls, resulting in the low product shear
and found that it had a high porous structure with thin cell walls force. Additionally, in this work, decreasing hardness of flakes
and large round-to-elongated air cells. Such morphological features probably affected by increasing of protein contents in peanut
are associated with the very high product expansion, low bulk flours. Mohamed (1990) found that the addition of protein content
density, and relatively poor structural integrity of the peanut product. ˆ25% resulted in decreased hardness of extruded product. The
Phillips and Falcone (1988) noted that fat in peanut flour apparently decrease in hardness could be due to the interference of starch-
acted as a lubricant and plasticizer, allowing greater expansion and starch interaction by protein molecules.
lower density. Suknark et al (1997) also found that the bulk density of
extrudates decreased when adding 15–30% partially defatted peanut Color
flour into various types of starch. Additionally, Bhatnagar and Hanna Increasing PDPF and R-PDPF content reduced lightness of the
(1997) observed the bulk densities of extruded products blended with flakes (Table VIII). The type of peanut flour also contributed. R-PDPF
corn starch and several oils and found that peanut oil resulted in darkened the samples more than nonroasted PDPF, particularly at
the lowest bulk density and shear strength, and highest porosity. In this the high (30%) level of peanut flour. Redness increased as levels
work, therefore, increasing the fat content by fortification with of PDPF and R-PDPF increased. Yellowness was decreased by
peanut flours would reduce the elasticity of collets as they are flaked, increasing PDPF and R-PDPF content.

WAI and WSI

TABLE V
Amino Acid Content (g/100 g of protein) WAI and WSI of extruded toasted flakes were related to those
of Partially Defatted Peanut Flour and Corn Conesa of the raw materials used for their preparation (Table VIII). WAI
of extruded toasted flakes containing 30% peanut flours was higher
Amino Acidsb Partially Defatted Peanut Flour Corn Cones
than the control. Neither adding 10 and 20% peanut flours nor the
Arginine 10.86 ± 0.09 2.58 ± 0.02 type of peanut flour affected WAI of the flakes. Other studies also
Histidine 1.57 ± 0.06 1.97 ± 0.30 reported the addition of protein ingredients increasing WAI values
Isoleucine 3.84 ± 0.07 3.13 ± 0.06
Lysine 3.42 ± 0.11 1.50 ± 0.18
of the products (Baker and Hin 1984; Bhattacharya et al 1986). An
Methionine 1.45 ± 0.11 2.07 ± 0.18 increase of peanut flours increased WSI of extruded toasted flakes.
Phenylalanine 5.60 ± 0.06 4.64 ± 0.27 Generally, WSI is related to the quantity of water-soluble molecules.
Threonine 2.66 ± 0.10 2.62 ± 0.04 Because flakes with added peanut flour had greater amounts of
Valine 4.54 ± 0.06 3.75 ± 0.01 protein than the control, the added protein increased water solu-
a Values are means ± standard deviations of duplicate determinations. bility of the flakes.
b Essential amino acids.

TABLE VI
Moisture Content (%) of Extruded Flakes at Different Stages of Processinga
Processing Stage
Material Before Preconditioning Entering Extruder Exiting Extruder Final Products
Corn cones only 11.8 ± 0.1 25.6 ± 0.1 19.8 ± 0.3 3.6 ± 0.1
10% PDPFb 11.3 ± 0.3 25.2 ± 0.6 19.5 ± 0.2 3.5 ± 0.1
20% PDPF 10.8 ± 0.1 24.9 ± 0.3 19.4 ± 0.3 3.3 ± 0.2
30% PDPF 10.3 ± 0.5 24.6 ± 0.4 19.1 ± 0.2 3.1 ± 0.1
10% R-PDPFc 11.0 ± 0.3 24.8 ± 0.3 18.8 ± 0.4 3.4 ± 0.1
20% R-PDPF 10.1 ± 0.1 24.4 ± 0.3 18.6 ± 0.2 3.2 ± 0.1
30% R-PDPF 9.3 ± 0.1 24.2 ± 0.2 18.3 ± 0.1 3.0 ± 0.1
a Values are means ± standard deviations from triplicate runs.
b Nonroasted partially defatted peanut flour blended by weight with corn cones.
c Roasted partially defatted peanut flour blended by weight with corn cones.

Vol. 79, No. 4, 2002 589

 TABLE VII
Proximate Composition (%) of Extruded Breakfast Cereal Flakesa
Flakes Proteinb Oil Ash Fiberc Carbohydrated
Corn cones only 6.74 ± 0.06i 0.93 ± 0.06i 2.28 ± 0.03i 0.73 ± 0.08i 89.32 ± 0.07f
10% PDPFe 10.66 ± 0.17h 1.35 ± 0.06h 2.59 ± 0.15h 0.93 ± 0.06h 84.47 ± 0.20g
20% PDPF 13.58 ± 0.21g 1.86 ± 0.12g 2.90 ± 0.06g 1.14 ± 0.05g 80.52 ± 0.76h
30% PDPF 16.60 ± 0.67f 2.37 ± 0.12f 3.10 ± 0.08f 1.44 ± 0.06f 76.49 ± 0.72i
10% R-PDPFf 10.86 ± 0.15h 1.38 ± 0.04h 2.65 ± 0.16h 0.95 ± 0.12h 84.16 ± 0.17g
20% R-PDPF 13.87 ± 0.25g 1.92 ± 0.08g 2.95 ± 0.13g 1.18 ± 0.08g 80.08 ± 0.33h
30% R-PDPF 16.98 ± 0.59f 2.43 ± 0.15f 3.16 ± 0.09f 1.48 ± 0.11f 75.95 ± 0.56i
a Values are means ± standard deviations of triplicate determinations (% db). Values followed by the same letter in the same column are not significantly
different (P < 0.05) using Duncan’s multiple range test.
b N ™ 6.25.
c Crude fiber, determined by Mid-Continent Laboratories, Inc., Memphis, TN.
d Determined by difference.
e Nonroasted partially defatted peanut flour blended by weight with corn cones.
f Roasted partially defatted peanut flour blended by weight with corn cones.

TABLE VIII
Physical and Physicochemical Properties of Extruded Breakfast Cereal Flakesa
Colorb
Flakes Bulk Density (g/L) Hardness (N) WAIc (g/g) WSId (g/100 g) L a b
Corn cones only 265e 3.07e 5.78 ± 0.20f 14.19 ± 0.18g 56.8 ± 0.2e 9.7 ± 0.1g 29.4 ± 0.1e
10% PDPFe 256f 2.76f 5.85 ± 0.12f 15.00 ± 0.48f 52.2 ± 0.8f 10.8 ± 0.4f 25.4 ± 0.4f
20% PDPF 248f,g 2.41g 5.93 ± 0.10e,f 15.61 ± 0.24e,f 49.1 ± 0.7g 11.2 ± 0.2e 22.7 ± 0.2g
30% PDPF 241g,h 2.05h 6.11 ± 0.08e 16.08 ± 0.54e 47.8 ± 0.2h 11.4 ± 0.1e 21.0 ± 0.1h
10% R-PDPFf 254f 2.65f,g 5.90 ± 0.11f 14.81 ± 0.53f 51.6 ± 0.5f 10.7 ± 0.3f 25.0 ± 0.4f
20% R-PDPF 245f,g 2.32g 5.95 ± 0.07e,f 15.52 ± 0.18e,f 48.4 ± 0.5g,h 11.5 ± 0.2e 22.7 ± 0.3g
30% R-PDPF 236h 1.99h 6.14 ± 0.08e 15.89 ± 0.38e 46.6 ± 0.6i 11.6 ± 0.1e 21.1 ± 0.5h
a Values are means ± standard deviations of triplicate runs. Values followed by the same letter in the same column are not significantly different (P < 0.05)
using Duncan’s multiple range test.
b L = brightness (0 = black, 100 = white); +a = red, –a = green; +b = yellow, –b = blue.
c Water absorption index is the weight of the gel obtained per gram of dry sample.
d Water solubility index is the amount of solids recovered by evaporating supernatant from water absorption tests, expressed as % of dry solids in sample.
e Nonroasted partially defatted peanut flour blended by weight with corn cones.
f Roasted partially defatted peanut flour blended by weight with corn cones.

TABLE IX constituents. The forming extruder allows previously sheared dough

Bowl Life of Experimental Flakes and Commercial Cornflakes to relax before being forced through the final die (Bailey et al 1991).
Flakes Bowl Life (min)a Furthermore, a cooling reel to cool the bead to  38–63°C, and a
tempering screw to assist in maintaining the temperature and moisture
Corn cones only 9.0eb
10% PDPFc 8.0f of the collets were not available in this study, making it difficult to
20% PDPF 7.0g make flakes with good texture. Finally, commercial cornflakes A and
30% PDPF 6.0h B took longer time to retain crispness after soaking in milk than com-
10% R-PDPFd 8.0f mercial cornflakes C, which was probably due to the extrusion process
20% R-PDPF 7.0g that provided both thermal and mechanical degradation.
30% R-PDPF 6.0h
Commercial cornflakes A 4.0i Sensory Evaluation
Commercial cornflakes B 4.0i
Commercial cornflakes C 3.0j Extruded toasted flakes were rated acceptable (average > 5.0) for all
a
attributes evaluated (Table X). No significant difference was found in
Subjective determination of time for disappearance of crispness of extruded sensory ratings for crispness of extruded toasted flakes. The samples
toasted flakes.
b Values followed by the same letter in the same column are not significantly containing 30% peanut flour were rated less acceptable than those
different (P < 0.05) using Duncan’s multiple range test (n = 3). containing higher percentages of corn cones. Some panelists com-
c Nonroasted partially defatted peanut flour blended by weight with corn mented that almost all of the samples were too hard due to limita-
cones. tions of the experiment described earlier. The addition of peanut
d Roasted partially defatted peanut flour blended by weight with corn cones.
flour significantly reduced the color acceptability of extruded toasted
flakes. Mean scores for color acceptability of extruded toasted flakes
Bowl Life containing peanut flour were 5.87–7.02, which is between “neither
The time that RTE breakfast cereal flakes retains crispiness after like nor dislike” to “like moderately”, indicating that inclusion of
wetting with milk is critically important. Flakes containing peanut 10–30% R-PDPF did not cause the color to be unacceptable.
flours took less time to become soggy than the control (Table IX). Flakes containing 10 and 20% R-PDPF provided flavor and overall
This was related to structural integrity, hydration capacity, solubility, acceptability compatible with that of the control. Flavor accept-
and density of the flakes. Flakes containing 30% PDPF disintegrated ability was difficult to evaluate because some panelists liked the
easily after a short time. Only experimental flakes containing corn peanut flavor very much, while others disliked it.
cones took longer time to become soggy than commercial cornflakes
C, which are produced by extrusion processing. The hardness of the Improvement of Peanut-Flavored Flakes
experimental flakes was due to limitations of the equipment to Flakes containing 30% nonroasted PDPF had the highest peanut
produce good quality flakes as commercial products. Because no flavor intensity score (Table X). The intensity of peanut flavor was
forming extruder was used in this study, apparently shortening the 1.31–5.33, which is relatively mild. The mild peanut flavor in extruded
extrusion cooking cycle resulted in less development of the matrix toasted flakes probably is the result of the 8% oil in PDPF.

590 CEREAL CHEMISTRY

 TABLE X
Sensory Evaluation of Extruded Breakfast Cereal Flakes
Sensory Scoresa
Flakes Crispnessb Colorb Flavorb Overall Acceptabilityb Flavor Intensityc
Corn cones only 7.10e 7.96e 6.44ef 6.73e 1.31h
10% R-PDPFd 6.69e 7.02f 6.73e 6.81e 2.33g
20% R-PDPF 7.08e 6.33g 6.08ef 6.19ef 2.89fg
30% R-PDPF 7.10e 5.89g 5.71fg 5.89f 3.46f
30% PDPFe 7.04e 5.87g 5.23g 5.58f 5.33e
a Values followed by the same letter in the same column are not significantly different (P < 0.05) using Duncan’s multiple range test (n = 48).
b Value represents mean scores from a nine point hedonic scale: 1 = extremely dislike, 9 = extremely like.
c Intensity of peanut flavor. Value represents mean scores from a nine point hedonic scale: 1 = none, 9 = strong.
d Nonroasted partially defatted peanut flour blended by weight with corn cones.
e Roasted partially defatted peanut flour blended by weight with corn cones.

Because much of the flavor is in the oil, defatted peanuts are less AOCS. 1993. Official Methods and Recommended Practices of the
flavor-intensive (Woodroof 1983). Additionally, extrusion tends to American Oil Chemists Society, 4th Ed. Method Ba 2a-38, Ba 3-38,
reduce flavors of products because of chemical degradation due to Ba 5a-49, Ba 6-84. The Society: Champaign, IL.
oxidation, hydrolysis, and other reactions. Much of the flavor is Ayres, J. L., and Davenport, B. L. 1977. Peanut protein: A versatile food
ingredient. J. Am. Oil Chem. Soc. 54:109A-111A.
normally lost to the atmosphere as the extrudate exiting at the die Bailey, L. N., Hauck, B. W., Sevatson, E. S., and Singer R. E. 1991.
(Maga 1989). Spadaro et al (1971) reported that the use of 15% Systems for manufacture of ready-to-eat breakfast cereals using twin-
full-fat roasted peanuts produced an extruded product with peanut screw extrusion. Cereal Foods World 36:863-869.
aroma; however, this aroma dissipated as the product cooled after Baker, J., and Hin, Y. S. 1984. High-protein rice-soya breakfast cereal. J.
extrusion. Prinyawiwatkul (1993) also found that peanut aroma is not Food Proc. Pres. 8:163- 174.
evident in cooled extruded products made with corn starch and Bhatnagar, S., and Hanna, M. A. 1997. Modification of microstructure of
peanut flour. starch extruded with selected lipids. Starch 49:12-20.
R-PDPF did not improve peanut flavor in the flakes. This is Bhattacharya, M., Hanna, M. A., and Kaufman, R. E. 1986. Textural
properties of extruded plant protein blends. J. Food Sci. 51:988-993.
probably because pyrazine compounds, the major flavor precursors of
Bookwalter, G. N., Warner, K., Anderson, R. A., and Bagley, E. B. 1978.
roasted flavor, are heat sensitive and rapidly vanished during the Cornmeal/peanut flour blends and their characteristics. J. Food Sci.
extrusion process, resulting in the mild flavor of extruded toasted 43:1116-1120.
flakes made with R-PDPF. In addition, flavor compounds are bound to Camire, M. E. 1989. The effects of protein-polysaccharide interactions
macromolecules such as starch and protein in the reactor zone of on the quality of extruded foods. MS thesis. Texas Woman’s Uni-
the extruder (Camire and Belbez 1996). versity: Denton, TX.
Camire, M. E., and Belbez, E. O. 1996. Flavor formation during
CONCLUSIONS extrusion cooking. Cereal Foods World 41:734-736.
Celis, L. P., Rooney, L. W., and McDonough C. M. 1996. A ready-to-eat
breakfast cereal from food-grade sorghum. Cereal Chem. 73:108-114.
This study showed that breakfast cereal flakes could be made
Hagan, R. C., Dahl, S. R., and Villota, R. 1986. Texturization of co-pre-
from combinations of corn cones blended with partially defatted cipitated soybean and peanut proteins by twin-screw extrusion. J. Food
peanut flour (PDPF) or roasted partially defatted peanut flour (R- Sci. 51:367-370.
PDPF) at different levels up to 30% using twin-screw extrusion. Sup- Harper, J. M. 1981. Extrusion of Foods, Vol. 1. CRC Press: Boca Raton,
plementation with peanut flours improved the nutritional charac- FL.
teristics of corn cones breakfast flakes. However, protein and fat Harris, H., Davis, E. Y., Van de Mark, M. S., Rymal, K. S., and Spadaro,
content in peanut flours also affected the density of those extruded J. J. 1972. Development and use of defatted peanut flours, meals, and
flakes, resulting in shorter bowl life. An addition of extruded grits. Auburn Univ. Agric. Exp. Sta. Bull. 431:1-71.
toasted flakes with ˆ20% R-PDPF were considered as acceptable Johri, T. S., Agrawal, R., and Sadagopan, V. R. 1988. Available lysine and
methionine contents of some proteinous feedstuffs. Ind. J. Anim. Nutr.
as those without peanut flour. The peanut flavor intensity score of
5:228-229.
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other RTE breakfast cereals or snacks should be further studied. Midden, T. M. 1989. Twin screw extrusion of cornflakes. Cereal Foods
World 34:942-943.
Miller, R. C. 1994. Breakfast cereal extrusion technology. Page 73-109
ACKNOWLEDGMENTS
in: The Technology of Extrusion Cooking. N. D. Frame, ed. Blackie
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We acknowledge financial support for this research from the Texas
Mohamed, S. 1990. Factors affecting extrusion characteristics of
Advanced Technology Program under the Grant No. 999903-251. Special
expanded starch-based products. J. Food Process. Preserv. 14:437-452.
thanks go to Insta Pro International, Wenger Manufacturing Co., for use
Phillips, R. D., and Falcone, R. G. 1988. Extrusion of sorghum and
of their extruders and providing technical assistance, and Birdsong
sorghum peanut mixtures: Effect of barrel temperature and feed
Peanuts Co. for donating peanuts for this research project.
moisture on physical-textural characteristics. J. Text. Stud. 19:185-197.
Prinyawiwatkul, W., Beuchat, L. R., Phillips, L. D., and Resurreccion, A.
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[Received August 13, 2001. Accepted March 14, 2002.]

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