Optimization of Process Variables and Formulation Parameters for Maize Flour-Based Flatbread Utilizing Response Surface Methodology

Abstract

Flat breads, commonly known as ‘chapati’ or ‘roti’ are the most consumed bread in India especially in north India. In rural north India, especially in Punjab ‘Sarsoka sag and Makki di roti’ is the signature dish during winter season. Maize flour based flatbreads are generally prepared by hand; this process is laborious, time consuming and requires expertise. The present investigation was planned to standardize the process parameters and formulations for mechanized preparation of maize flour based flatbread using response surface methodology. The central composite rotatable design (CCRD) was used with independent variables i.e. resting time of dough (0–20 min), blending ratio of supplement flour (20–40%) and temperature of water (18–36°C). The results of the study revealed that the process parameters had a significant effect (p<0.05) on moisture content, browning index, peroxide value, free fatty acid, cutting force, colour change and overall acceptability of flatbread. The models obtained had a high coefficient of determination (R² ≥ 0.99) and were quite significant. The optimum process conditions obtained by numerical optimization technique for maize flour based flatbread blended with gram flour were; dough resting time 12.45 min, blending ratio 38.90% and temperature of water 31.47°C; likewise maize flour based flatbread blended with wheat flour were obtained as dough resting time 20 min, blending ratio 20% and temperature of water 29.68°C. The present investigation showed that addition of wheat and gram flour in flour mix helped in preparation of quality flatbread and meets the nutritional requirements of developed product.