Design of extruded grain slices with phytoconcentrates

This study's object is extruded cereal slices with added phytoconcentrates of wild plants (sea buckthorn and hawthorn). The task addressed is to provide a stable crispy structure while maintaining nutritional value and food safety. A comprehensive physicochemical and mechanical assessment was conducted for nine formulations containing buckwheat, wheat, corn, millet, and rice, along with fruit components. Moisture content (7.8–8.5%), acidity (2.5–2.9 °T), and ash content (1.2–1.9%) have been determined. Instrumental texture analysis revealed that the highest hardness (up to 460 g/mm) and breaking force (up to 3922 g) were observed in samples containing corn and wheat, whereas buckwheat-based slices exhibited the highest deformation (up to 9.3 mm), indicating a softer and less brittle texture. To quantify the contribution of formulation to texture, a regression model was built by using the partial least squares (PLS) method: coefficient of determination R2 = 0.69, adjusted R2 = 0.64, p = 0.0056. The key variables in the model were slice type (VIP = 0.913) and breaking force (VIP = 0.777). Principal component analysis (PCA) confirmed that corn- and wheat-based samples correlate with crispness, whereas buckwheat and hawthorn acted as softening agents. Fruit additives moderately increased brittleness due to caramelization and acidity changes. Process stability was confirmed using X and Moving R control maps. The results are attributed to low residual moisture (< 9%), porous structure, as well as balanced composition. The proposed instrumental approach allows for prediction of textural outcomes in new formulations and could be applied to devise functional snacks and bread substitutes for dietary nutrition