Production of deep-fried corn chips using stale bread powder: Effect of frying time, temperature and concentration

- The stale bread was successfully utilized in the production of corn chips.
- Oil content of corn chips decreased (by 15%) with the incorporation of stale bread.
- Sensory evaluation revealed that the chips with stale bread (by 25%) flour were more preferred.
- The stale bread can be used as a cover matter and also as an enrichment agent in snack foods.

In this study, utilization of stale bread powder was evaluated to produce low fat snack food formulation and for this purpose, corn chips were manufactured using stale bread at different concentrations. Response surface modeling technique was used to study the simultaneous effects of stale bread level (0-50%), frying time (40-60 s) and frying temperature (170-190 °C) on some physicochemical, textural and sensory properties of corn chips enriched with stale bread powder. Also, optimization of processing variables was performed for desired products. Results indicated that the addition of stale bread into the formulation decreased the oil content of the final product up to addition of 25% stale bread level. The hardness and yellowness of samples decreased with the increasing of stale bread level; while, the dry matter and ash contents as well as firmness value and sensory scores of samples increased with the increasing stale bread level. Generally, corn chips produced with the addition of stale bread were more preferred by the panel compared to control samples.