The recycling of brewer's processing by-product into ready-to-eat snacks using extrusion technology

Brewer's spent grain (BSG) is the main by-product of the brewing industry. The incorporation of BSG into ready-to-eat expanded products and its effects on the textural and functional properties of extrudates have been studied. Dried and milled BSG at levels of 10–30% was added to the formulation mix made of wheat flour, corn starch and other ingredients. The results obtained from the analysis of the extrudates are discussed in terms of the interaction between the ingredients and effects of processing conditions. The samples were processed in a twin-screw extruder with a combination of parameters including constant feeding rate of 25 kg/h, process temperatures 80–120 °C and screw speeds of 150–350 rpm. Pressure, torque and material temperature during extrusion were recorded. The extrudate properties of nutritional and textural characteristics were measured. Image technique investigations provided useful information on internal structure of the extruded products, total cell area, and their contribution to the appearance and texture. It was found that addition of BSG significantly increased protein content, phytic acid and bulk density, decreased sectional expansion index, individual area and total area of the cells. The higher level of BSG resulted in cells with thicker walls with a rougher surface.