Micronization of Whole Grain Flours: Innovative Approaches for Improving Functional Characteristics and Product Performance

ABSTRACT Rising consumer demand for nutrient‐dense cereal products has renewed interest in whole‐grain ingredients, yet the coarse texture and altered functional behavior of whole‐grain flours limit their application in many foods. Micronization, the controlled reduction of particle size by mechanical or thermal–mechanical approaches (e.g., ball, jet, roller, cryogenic, ultrafine, and IR‐based methods), can modify flour microstructure and molecular organization. This review investigates recent studies on micronization of whole‐grain flours, comparing techniques and summarizing their effects on structural, physicochemical, techno‐functional, thermal, and rheological properties, and final product quality. It also evaluates benefits and trade‐offs (e.g., improved digestibility and bioactive release vs. excessive starch damage and energy costs), and highlights analytical methods and application‐specific optimization strategies. Micronization is a promising, sustainable route to reconcile whole‐grain nutrition with consumer‐acceptable functionality: appropriately reduced particle size enhances hydration, pasting behavior, bioactive release, and dough handling, improving texture and shelf life in many applications. However, over‐micronization can increase damaged starch, weaken starch–protein networks, and impair product quality, so process parameters must be tailored to grain type and intended use. Future work should prioritize scale‐up, combined modification strategies (e.g., enzymatic or hydrothermal pairing), and targeted studies of digestibility and glycemic response to fully realize micronization's potential.