Nutritional, Functional and Physical Impact of Fortification of Corn Extrudates with Cocoa Pod Husks and Brewer's Spent Grains: Effect of Extrusion Processing

The incorporation of brewers’ spent grains (BSG) for food applications has been widely explored due to their high protein, dietary fiber, and bioactive compounds. Additionally, pectin has been shown to improve the texture and expansion of fiber-based extrudates. Cocoa pod husk (CPH), a by-product of cocoa production, is a natural source of pectin, antioxidants, and fibers, yet its use in functional food manufacturing remains unexplored. Therefore, this research aims to explore the potential use of BSG and CPH as functional ingredients in corn-based extrudates. The optimized formulation (10.2 wt.% BSG, 9.8 wt.% CPH) extruded at high temperatures and 30% feed moisture resulted in high polyphenol content (1.855 mg GAE/g), antioxidant capacity (0.2542 µM Trolox eq/g), WSI (15.479%), and WAI (0.8393 g/g). Additionally, the extrudate's low oxalate content (2.25 mg/100 g) ensures its nutritional safety. The combination of these by-products enhanced the functional and physicochemical properties of the extrudate, making it a promising ingredient for the development of health-oriented snacks. These findings highlight the potential of BSG and CPH as functional ingredients, improving the nutritional value of extruded products while contributing to food waste reduction. Future studies should assess sensory attributes and optimal formulations to maximize consumer acceptance.