Innovative corn extrudates incorporating barley-oat flour blends: Nutritional, functional, and sensory evaluation

Ready-to-eat snacks are widely consumed; however, they are often energy-dense while lacking adequate protein and micronutrients. Most RTE snacks are predominantly composed of carbohydrates and have a high glycemic index, which has been associated with various health concerns, including cardiovascular diseases, hypertension, and an increased risk of diabetes. This study aimed to enhance the nutritional profile of corn extrudates by incorporating a barley-oat flour blend at five different levels (10–50%). The extrudates were produced using a twin-screw extruder, with corn flour partially replaced by a barley-oat flour blend at varying levels (10–50%). The results demonstrated that replacing 50% of corn flour with the barley-oat flour blend significantly (p < 0.05) increased protein and crude fiber content by 65.17% and 42.81%, respectively. The antioxidant activity (DPPH) and crude fiber content were significantly enhanced by 1.59-fold and 1.82-fold, respectively, compared to the control sample. However, the expansion ratio and porosity of the extrudates decreased significantly (p < 0.05) with the incorporation of the barley-oat flour blend. Sensory evaluation indicated that corn extrudates with up to 20% substitution (10% barley flour and 10% oat flour) were organoleptically acceptable. Therefore, the incorporation of a barley-oat flour blend presents a viable approach for developing nutritionally enriched extrudates with improved health benefits, addressing dietary deficiencies while maintaining consumer acceptability.