Nixtamalization and Extrusion Processes: Effects on Physicochemical, Nutritional, and Nutraceutical Properties in the Processing of Corn Into Tortilla

Corn is a vital cereal produced globally, especially in Mexico and other Latin American countries, where it is a daily dietary staple, primarily consumed in various corn products prepared through nixtamalization. Tortillas are a significant component of the Mexican diet, serving as a major source of protein and energy. The average consumption of nixtamalized corn tortillas in Mexico is around 80 kg per capita per year. Tortilla production, over 12 million tons annually, is a key sector in Mexico’s food industry, ranging from artisanal to industrial methods. Tortillas are made from fresh nixtamal masa , instant nixtamalized corn masa flour, or both. More than 50% of the tortillas in Mexico are commercially produced and distributed through various channels. Consumer preferences vary regionally, with instant corn masa flour tortillas favored in the north and fresh nixtamal masa tortillas preferred in central and southern Mexico. Globally, tortillas are usually made from instant masa flour. The instant flour offers advantages such as vitamin and mineral enrichment, easier handling, and longer shelf life (about 3 months), compared to fresh nixtamal masa , which typically lasts only 4–24 h depending on storage conditions. However, the nixtamalization process requires a substantial consumption of water and energy, and their byproduct, known as nejayote , contributes to water pollution. Mexico alone produces approximately 14.4 million cubic meters of nejayote daily, which negatively impacts the environment due to its highly alkaline pH (> 10). In response to these challenges, the scientific community has been exploring alternative methods to reduce resource consumption and mitigate the environmental impact of tortilla production, focusing on processes such as extrusion cooking. While nixtamalization by extrusion presents a potential alternative, previous studies have highlighted significant starch damage that affects the rheological, functional, and textural attributes of the corn, impacting the quality of instant corn masa flour, fresh nixtamal masa , and tortillas, as well as consumer acceptance of nixtamalized products. Therefore, the objective of this review is to describe in detail the nixtamalization and extrusion processes utilized in tortilla production, including the requirements and elements involved in both processes, as well as their advantages and disadvantages. In past research and articles about nixtamalization and extrusion processes, the data and information contained within them are insufficient to thoroughly explain the modifications that occur along these processes and how those changes could affect the characteristics that consumers expect from the final product. The relevance of this investigation in food science and technology revolves around the comparison of traditional nixtamalization and extrusion to determine their viability as alternative methods to produce maize‐derived products to diminish the use of resources and pollutants identified in the traditional nixtamalization process.