Impacts of ethanol-plasticization and extrusion on development of zein network and structure of zein-starch dough

To improve the viscoelasticity of zein in gluten-free dough, ethanol-plasticization and extrusion modification were employed. The peak viscosity of UZS (unextruded zein-starch) flour and EZS (extruded zein-starch) flour with ethanol (10 %, v/v) increased from 1340.0 to 1996.5 mPa·s and 1336.3 to 2291.5 mPa·s, and the bound bromophenol blue increased from 7.1 μg to 10.6 μg and 5.3 μg to 5.9 μg, respectively. Ethanol-plasticization enhanced zein's hydrophobic interactions and promoted zein network development, thus improving dough compatibility. However, the dense structure of the extruded zein made ethanol inaccessible to the interior, and the structural improvement on extruded zein-starch dough was limited. A model was developed to explain the influences of extrusion and ethanol-plasticization on the behavior of zein in the dough. Extrusion reduces the fiber-forming ability of zein, while ethanol-plasticization facilitates extensive fibrous network formation. This study provides a sound basis for the development of zein in gluten-free foods.