APPLICATION OF FREEZE-DRIED PASSION FRUIT IN BEAN STARCH-BASED EXTRUDED SNACKS PRODUCTION

Direct-expanded snacks were developed from bean starch (BS, 18% protein content) incorporated with freeze-dried passion fruit powder (FDPF) to enhance the utilization and value of plant-based ingredients in expanded food systems. Formulations containing 84% BS and 16% FDPF were processed using a twin-screw extruder from Thermo Fisher Scientific (Process 16 hygienic) at three feed rates: 3000 kg/h (RF-A), 3600 kg/h (RF-B), and 3900 kg/h (RF-C). The resulting products were characterized regarding moisture content, water activity (Aw), apparent density, color attributes (L* and b*), three-point bend (TPB), and texture profile analysis (TPA) to determine the impact of processing conditions on physicochemical and structural properties. Feed rate significantly affected the quality attributes of the extrudates. Moisture content increased progressively with higher feed rates, reaching 5.83%, 7.20%, and 9.07% for RF-A, RF-B, and RF-C, respectively. This result may be associated to limitation of moisture evaporating during extrusion, resulting in a greater residual moisture in the final products. Nevertheless, all samples presented Aw values below 0.60, indicating adequate microbiological stability and suitability for prolonged storage. Apparent density decreased as feed rate increased, suggesting enhanced expansion and the formation of a more porous and aerated internal structure. Color measurements revealed a reduction in luminosity (L*) accompanied by increased yellowness (b*) at higher feed rates, resulting in darker and more intense coloration. Texture analyses demonstrated that RF-A exhibited the highest hardness (158.9 N) and fracturability (15.3 N), indicating a denser and more compact structure with greater resistance to compression and fracture. In contrast, RF-B showed a pronounced reduction in hardness (21.4 N) and fracturability (5.57 N), suggesting the formation of a lighter and more expanded matrix. RF-C also presented low hardness (24.2 N) and very low fracturability (1.44 N), indicating a highly expanded and fragile structure. Overall, the results demonstrate that the incorporation of protein-rich bean starch and freeze-dried passion fruit powder represents a promising strategy for developing innovative direct-expanded snacks with desirable technological, structural, and sensory-related characteristics.