Recovered residue from corn flake processing and its application in modified flours and arepa bread

Abstract BACKGROUND The aim of this study was to evaluate the physicochemical and technological characteristics of corn flake processing residue, as well as its modified flours obtained through extrusion, heat–moisture treatment (HMT) in a drying oven, and HMT in direct‐steam autoclaving. A secondary aim was to compare the sensory acceptance and purchase intent of arepa bread with partial replacement of the residue by the selected modified flour to assess the potential utilization of this residue. RESULTS The extruded residue flour (ERF) exhibited a geometric mean diameter of 556.89 μm, classifying it as a medium flour. Extruded residue flour showed the highest values for b* (32.59) and C* (32.76), making it ideal for producing yellowish foods such as baked goods. The ERF also demonstrated the highest cold viscosity (319.67 cP), water absorption index (13.49 g g −1 ), and water solubility index (58.96%), indicating its suitability for gluten‐free products like arepa bread. The ERF exhibited a high transition temperature (T peak = 116.50 °C) and low enthalpy (1.12 J g −1 ), suggesting the formation of amylose‐lipid complexes and complete starch gelatinization. Due to its favorable properties, ERF was selected for arepa bread formulations. The formulation with the highest sensory acceptance combined 70% residue and 30% ERF (PA30), achieving an acceptability index of 77%, and offering a good macronutrient profile. CONCLUSION Using the residue and its extruded modified flour in arepa bread is feasible and could increase the sustainability of the corn industry while adding value to the residue. © 2026 Society of Chemical Industry.