Comparative Analysis of Roller Milling Strategies on Wheat Flour Physicochemical Properties and Their Implications for Microwave Freeze-Dried Instant Noodles

The milling process is a critical technological step that regulates wheat flour characteristics and ultimately determines end-product quality. This study systematically evaluated the effects of three key milling parameter adjustments in a laboratory-scale roller mill-double sifting (2S), double break milling (2BM), and increased roll gap (IRG)-on the physicochemical properties of wheat flour and the quality of microwave freeze-dried non-fried instant noodles. The results demonstrated that milling processes significantly influenced the particle size and composition of flour. The 2BM-IRG process increased the volume mean diameter of flour to 86.38 μm, while significantly improving flour extraction rate (69.80%), protein content (10.98%), and ash content (0.54%). In contrast, the 2S process significantly reduced the volume mean diameter (65.27 μm). These changes in flour properties directly affected noodle quality-noodles made from 2BM-IRG flour exhibited the highest rehydration ratio but also the greatest cooking loss, along with the lowest expected glycaemic index (eGI); noodles produced from 2S flour showed the highest hardness, while the 2BM process endowed noodles with superior elasticity. A correlation analysis revealed that the digestibility characteristics of noodles (eGI) were predominantly and significantly influenced by flour protein and ash content (<i>p</i> < 0.01), while also being significantly affected by particle size (<i>p</i> < 0.05). The study confirmed distinct quality trade-offs between different milling strategies. Therefore, by optimizing combinations of break milling and sifting processes, it is possible to develop specialized flour tailored for specific quality requirements.