Evaluating the 3D printability of pearl millet flour with banana pulp blends

Abstract

AbstractBackgroundThree‐dimensional (3D) food printing is a promising method for developing nutritious snack foods with complex and customized structures. In this study, to develop a pearl millet‐based snack formulation, the printability of pearl millet flour (PMF) was assessed, without and with the addition of banana pulp (BP), a natural taste and flavor enhancer, at five different levels (PMF:BP of 100:0, 80:20, 60:40, 40:60, 20:80 and 0:100).ResultsThe water activity significantly decreased with increases in the proportion of BP; higher water activity was exhibited at 100:0 (0.99). The BP proportion influences all the color values (redness: 2–11; yellowness: 17–31.87; total color difference: 2–17). All formulations exhibited shear‐thinning behavior (n = 0.02–0.49) and higher hardness (0.2–0.4 N), but not all were printable. A significant decrease in adhesiveness (−0.2 to −0.03 N s) and higher storage modulus (2000–6000 Pa) occurred with an increased proportion of BP. Findings from detailed rheological behavior assessment (static, dynamic and three‐interval thixotropy tests) better correlated with trends observed during 3D extrusion printing. The highest yield stress was attained (80 Pa) in the 100:0 formulation. From the thixotropy test, more deformation (>80%) and recovery (>100%) were attained by three of the formulations (100:0, 80:20, 60:40). Overall, the best constructs were obtained (based on the visual sensory characteristics) for the 60:40 formulation printed at 600 mm min−1 printing speed and 240 rpm extrusion motor speed through a 1.22 mm nozzle.ConclusionThe findings of this work will provide valuable insights into the development of novel millet‐based 3D printed foods. © 2024 Society of Chemical Industry.