Explosion Puffing of Native Mexican Maize: Physical Variables and Quality Assessment

Snack consumption has become increasingly prevalent in modern dietary habits, largely driven by convenience. Puffed kernels represent a type of snack produced through the explosion puffing method, in which starch expansion is induced by pressure differentials. This study aimed to evaluate the puffing potential of different native maize populations by the explosion puffing method, identify variables associated with high-quality puffed kernels, and determine the proximate composition and total soluble phenol content of both raw and puffed kernels. The flotation index ranged from 5% to 98%, and maize samples was classified by endosperm hardness as very hard, hard, intermediate, soft, or very soft. Despite the wide variability in vitreous endosperm percentage, all hardness categories exhibited had a high proportion of puffed kernels (> 86.7%) and expansion volume between 10.1 and 26.6 cm³ g^-1. Puffed kernels showed low moisture content (3.0%-3.6%), a porous and crunchy texture, high compressive force, and a preserved nutrient composition. Furthermore, the total soluble phenol content was higher in puffed kernels compared to their raw counterparts. This study provides an initial approach to utilizing dent maize for puffed kernel production, and demonstrates the effectiveness of explosion puffing in processing maize varieties with diverse physical characteristics. PRACTICAL APPLICATIONS: In Mexico, there is a wide diversity of maize that varies in size, color, shape, and hardness. Limited research has been conducted on the production of maize-based puffed products. In this study, we found that the explosion puffing method allows us to work with maize in a wide range of hardness, from very hard to very soft, but the highest puffing quality was achieved with hard and very hard maize. In the food industry, the use of this processing method can be promoted to process maize with varying hardness levels and to develop healthier snack alternatives, since the puffed kernels retain the nutritional properties of the raw kernel, including proteins and carbohydrates, while increasing their phenolic content.