Use of flours from traditional pan and salt‐bed‐roasted Kodo grains in the production of breakfast cereal: Spatial, morphological, techno‐functional, structural, and rheological analyses

Abstract Kodo millet, possesses the goodness of iron and low glycemic index, notably, its starch has inadequate application owing to retrogradation and low amylose content. Dry‐roasting seems worthy as an inexpensive pretreatment process to preserve desirable textural characteristics of whole cereal grains with peculiarity of moisture levels below 20% for a very short time. The aim of this work was to analyze indepth studies to explain morphological, techno‐functional, structural, and rheological transformation of Kodo starch components generated during roasting of conditioned whole kernels at 15% and 20% initial moisture content (IM). The micrographs displayed a honeycomb‐like structure in all roasted flours. The X‐ray diffraction intensity decreased and showed partial rupture to A‐type orthorhombic crystals of Kodo starch after roasting, while lamellar growth across the multilayer matrix was also generated (23° and 37.35°). The fusion of the starch granules with endosperm's macromolecules observed plausible techno‐functional, and rheological properties, emphasized as non‐nutritional properties substantially improved sensory attributes of food as an additive. Roasted flour at higher IM thus made it easier to integrate into instant ready‐to‐eat breakfast cereals of improved amylose content (23.69%–29.31%) with lowered water activity (.4671–.5170) of varied skin strength (196.17–1894.41 g), elasticity (4.03–10.21 mm), and cell size (164.03–1059.10 μm) detected from puncture‐test force measurement. The infrared absorbance band illustrated loss of peak at 1047 cm −1 and endosperm's expansion (195.34%–309.30%) lowered kernel hardness (42.3–17.78 N) indicated structural loss upon roasting, may significantly reduce milling cost, and provide a commercially pretreated readied kernel or flour for industrial applications. Practical applications Kodo millet, of the Poaceae family thrives well in abiotic stress and scanty rainfall exhibit meager application owing to low amylose content. Applying preprocessing traditional roasting techniques upon moistened kernel, get popped cereal. Milling of such cereal retards subcellular loss, indicating increased amylose, water, and oil absorption with avid aroma. This is critical in the preparation of cost‐effective dietary formulations for children and geriatrics, thus making it easier for integration into ready‐to‐eat wholesome breakfast cereals.