A multihole nozzle controls recrystallization of high-moisture extruded maize starches: Effect of cooling die temperature

Hot extrusion is utilized for starch modification due to its high mechanical input and product output. Amylose recrystallization commences and primarily depends on intermolecular interactions after conventional extrusion. Hence, the design of a new component based on the existed extrusion system was aimed at facilitating molecular aggregation, potentially accelerating starch recrystallization. In this study, a nozzle sheet comprising 89 holes was integrated into the cooling die. The impact of the multihole nozzle on the structure and in vitro digestibility of extruded maize starches after retrogradation was examined at varying cooling die temperatures. The results showed that the nozzle-assembled extrusion system operated effectively without additional mechanical or yield losses. At 50 °C, the crystallinity of nozzle-produced starch was approximately 70 % higher than that of conventionally extruded starch, predominantly owing to the B-type allomorph of the amylose double helix. Recrystallized amylopectin was also found in these nozzle-produced starches, indicating that multihole nozzle-induced uniaxial elongational flow resulted in the rapid starch crystallization. The increased formation of recrystallized amylose led to improved molecular order in starch structures while reducing their digestibility. These findings revealed a new approach to improve starch crystallinity by incorporating a nozzle sheet in the extrusion process.