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The effects of ingredients on popcorn popping characteristic

Article in International Journal of Food Science & Technology · February 2004

DOI: 10.1111/j.1365-2621.2004.00793.x

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International Journal of Food Science and Technology 2004, 39, 361–370 361

The effects of ingredients on popcorn popping

characteristics

Mehmet Ceylan & Erşan Karababa*

Department of Food Engineering, Faculty of Engineering, University of Mersin, Çiftlikköy, Mersin, Turkey
(Received 12 November 2001; Accepted in revised form 9 July 2003)

Summary Response surface methodology was used to evaluate the effects of ingredients on popcorn
popping characteristics. The effects of different ingredients on the expansion volume and
unpopped kernel ratio of popcorn in a conventional popper and a microwave oven were
evaluated and optimized by response surface methodology. The regression models were
significant and had R2 value in the range of 0.919–0.956. The optimum levels of ingredients
for microwave popping were 4.4% salt, 5.9% vegetable oil, 0% sodium bicarbonate and
16.4% butter, this formulation giving an expansion volume of 33.1 mL g)1. In the case of
conventional popping, the maximum expansion volume of 37.3 mL g)1 was obtained for
3.5% salt, 6% vegetable oil, 0.10% sodium bicarbonate and 12.9% butter.
Keywords Conventional popping, expansion volume, microwave popping, optimization, unpopped kernel ratio,
response surface methodology.

property of popcorn is affected by several factors,

Introduction
i.e. kernel size (Willier & Brunson, 1927; Eldredge
Popcorn is an important snack food made from & Lyerly, 1943; Haugh et al., 1976; Hoseney et al.,
corn and is growing in popularity day by day in 1983; Lin & Anantheswaran, 1988; Allred-Coyle
Turkey. Most popcorn is sold unpopped at retail et al., 2000), kernel shape (Lyerly, 1942; Eldredge
stores and popped at home. The rest is sold at & Lyerly, 1943; Haugh et al., 1976; Hoseney et al.,
movies, fast food shops, bars, parks and other 1983; Pordesımo et al., 1990), endosperm type
recreational places. Within the microwave food (Lyerly, 1942; Hoseney et al., 1983), test weight
products sector, microwave popcorn is becoming (Eldredge & Lyerly, 1943; Eldredge & Thomas,
increasingly popular. In spite of its popularity, 1959; Haugh et al., 1976; Hoseney et al., 1983)
there are some problems associated with the moisture content (Eldredge & Lyerly, 1943; Hose-
popping quality of microwave popcorn such as ney et al., 1983; Lin & Anantheswaran, 1988;
low expansion volume, a high number of Metzger et al., 1989; Song & Eckhoff, 1994;
unpopped kernels and scorching of the popped Allred-Coyle et al., 2000), pericarp thickness
kernels (Schiffmann, 1986; Levy, 1988; Lin & (Hoseney et al., 1983. Stroshine et al., 1987;
Anantheswaran, 1988). Mohamed et al., 1993), structural damage
Popcorn quality is measured primarily by the (Eldredge & Lyerly, 1943; Walton, 1968; Hoseney
expansion volume and the number of unpopped et al., 1983; Lin & Anantheswaran, 1988), and
kernels (Song et al., 1991). The expansion volume genotpye (Haugh et al., 1976; Lin & Ananthes-
is a very important criterion for popcorn quality. waran, 1988; Song et al., 1991; Song & Eckhoff,
Commercial buyers purchase popcorn by weight 1994; Allred-Coyle et al., 2000). Many studies
and sell the popped corn by volume (Lyerly, 1942; have evaluated popping behaviours of popcorn in
Matz, 1984; Song et al., 1991). The popping hot air and oil poppers (Metzger et al., 1989;
Dofing et al., 1990; Song et al., 1991; Song &
*Correspondent: Fax: 90 324 3610032; Eckhoff, 1994). However, few studies have
e-mail: [email protected]; [email protected] investigated the factors affecting popping
doi:10.1111/j.1365-2621.2004.00793.x
Ó 2004 Blackwell Publishing Ltd
362 Effects of ingredients on popcorn popping M. Ceylan and E. Karababa

characteristics in a microwave oven using different method reported by Lin & Anantheswaran (1988)
ingredients (Singh & Singh, 1999). In addition to were used. A 15 g sample was popped. An
other factors, popping methods (Schiffmann, Arçelik MD-572 microwave oven (Arçelik Inc.,
1986; Lin & Anantheswaran, 1988, Dofing et al. _
1330 W, 50 Hz, 2450 MHz, Istanbul, Turkey)
l990, Mohamed et al., 1993) also affected the was used at the 850 W power setting to pop the
popping characteristics (Singh & Singh, 1999), and kernels. The actual power output of the micro-
addition of various ingredients improved the wave oven, measured by the IEC test was found
sensory properties of popcorn. Salt, vegetable to be 715 W (Buffler, 1992). A 1 L beaker
oil, butter, sugar syrup and other ingredients are containing the popcorn sample was placed at
used as a base material for flavours. the centre of the microwave oven and heated for
The objectives of this study were to establish the 2 min. Another small beaker was placed in the
relationship between the ingredients affecting the centre of the beaker. Thus, popped kernels were
popping characteristics of popcorn, in both con- kept away from the centre of the beaker and
ventional and microwave methods, and the protected from scorching during the test. After
responses that are relevant to the expansion each test the door of the oven was kept open for
volume and unpopped kernels as well as to 3 min to cool.
establish the optimum ingredients formulation
for obtaining maximum expansion volume and
Quality measurements
minimum unpopped kernels.
The expansion volume of the sample was meas-
ured in a 1 L graduated cylinder (Allred-Coyle
Materials and methods
et al., 2000) and expressed mL g)1 of kernels. The
number of unpopped kernels was determined by
Materials
transferring the popped corn to an 8 mm round-
One popcorn variety (Ant-Cin 98), which was hole screen, and expressed as a percentage of the
obtained from the Mediterranean Agricultural total number of kernels.
Research Institute in Antalya, Turkey, was used
in the experiments. Salt vegetable oil, sodium
Experimental design and statistical analysis
bicarbonate, and butter were obtained from a
local market. Moisture was determined in tripli- A second-order rotatable central composite design
cate according to American Association of Cereal was selected as an appropriate experimental
Chemists (AACC) Method 44–15A (AACC, design. The central composite design, developed
1999). The mean moisture content of the variety by Box & Wilson (1951) and their successors, is
was 12.2%. used for fitting second-order response surface
equations. Response surfaces predict each re-
sponse that can be measured with uniform
Methods
variance for all experimental factor settings within
Conventional popping a set radius of the design centre.
Samples were popped in a West Bend Stir Crazy The central composite design was composed of
(IKW Popper, The West Bend Company, West three types of design points: sixteen factorial
Bend, WI, USA). A 25 g sample was popped. points, eight axial points, and two centre points.
Kernels were counted and recorded before each Experimental runs were coded at levels of )1 and
popping. Popping was continued until completion +1 for the low and high levels of the factorial
(Count of 5 s after the last kernel popped, Song points, )2 and +2 for the low and high levels of
et al., 1991). axial points, respectively, and the centre point was
0 for each factor (Table 1). Factorial points were
Microwave popping determined as a percentage distance of )1 from )2
All ingredients were combined and mixed well. and of +1 from +2.
The mix was uniformly spread on the popcorn Twenty-six experimental runs covered the
samples in the mixer. Some modifications of the eighty-one possible combinations, each for four

International Journal of Food Science and Technology 2004, 39, 361–370 Ó 2004 Blackwell Publishing Ltd
 Effects of ingredients on popcorn popping M. Ceylan and E. Karababa 363

Table 1 Variables and their levels for the central composite the dependent variables (unpopped kernel ratio
design and expansion volume), regression analysis was
Coded levels
performed using the central composite design. The
regression model for the dependent variables (Y)
)2 )1 0 +1 +2 in terms of the independent variables was:
Independent
Symbol variables Factor levels (%) X
k X
k X
k
Y ¼ b0 þ bi xi þ bii x2i þ bi;j xi xj ð1Þ
Xs Salt 0 2 4 6 8 i¼1 i¼1 i;j¼1
Xo Vegetable oil 0 5 10 15 20
Xc Sodium bicarbonate 0 0.05 0.10 0.15 0.20 Where Y is dependent variables (unpopped kernel
Xb Butter 0 5 10 15 20 ratio, expansion volume), b0 the constant, bi the
linear coefficients, bii the quadratic coefficients and
independent variables: salt (X1), vegetable oil (X2), bij the cross product coefficients, xi and xj are the
sodium bicarbonate (X3), and butter (X4) which levels of the factors and k is the number of
were considered the important ingredients affect- independent factors.
ing the popcorn popping properties. This design
was used for each of the popping methods Statistical analyses
separately.
Response surface methodology was used to The data were evaluated to fit and optimize a
optimize popcorn popping quality. Two responses quadratic response surface to both dependent
were measured: expansion volume and unpopped variables, separately. Experimental data were
kernel ratio. A high value of expansion volume analysed by Statistica (Statsoft, 1995) software.
and a low unpopped kernel ratio imply optimal The contour plots were obtained for the data
product quality. To predict the relationships for generated from the final equation using Statistica

Table 2 Estimated coefficients of

the fitted quadratic equation for Estimated coefficients
expansion volume and unpopped
Conventional popping Microwave popping
kernel ratio
Expansion Unpopped Expansion Unpopped
Coefficients volume kernels volume kernels

Linear
XS 1.76 (0.30)* 0.10 (0.14) 0.003 (0.19) 0.14 (0.21)
Xo 0.74 (0.12)* )0.42 (0.05)* 0.17 (0.07) )0.64 (0.08)*
Xc 79.30 (12.30) )10.83 (5.72) 13.95 (7.71) )21.29 (8.59)
Xb 1.88 (0.12)** )0.74 (0.06)** 1.13 (0.08)** )1.76 (0.09)**
Quadratic
XS )0.35 (0.02)** 0.15 (0.01)** )0.16 (0.01)* 0.08 (0.02)*
Xo )0.04 (0.004)** 0.03 (0.002)** )0.02 (0.002)* 0.04 (0.003)**
Xc )331.49 (45.02)* 32.53 (21.43) 29.90 (28.85) 100.27 (32.15)
Xb )0.07 (0.004)** 0.04 (0.002)** )0.04 (0.002)** 0.05 (0.003)**
Cross-product
XS Xo 0.06 (0.01)* )0.03 (0.005)* 0.05 (0.007)* )0.08 (0.008)*
XS Xc )2.66 (1.22) 1.44 (0.58) )2.13 (0.78) )0.64 (0.87)
XS Xb 0.04 (0.01) )0.09 (0.005)** 0.06 (0.008)* )0.006 (0.008)
Xo Xc 0.33 (0.48) 1.05 (0.23)* )1.05 (0.31) 0.06 (0.34)
Xo Xb )0.03 (0.005)* )0.003 (0.002) )0.01 (0.003) 0.02 (0.003)*
Xc Xb )0.16 (0.49) )0.47 (0.23) )1.14 (0.32) 1.03 (0.35)
R2 0.939 0.956 0.919 0.949

Significant level: *P < 0.05, **P < 0.01.

Xs, salt; Xo, vegetable oil; Xc, sodium bicarbonate; Xb, butter.
S.e. values are in parenthesis.

Ó 2004 Blackwell Publishing Ltd International Journal of Food Science and Technology 2004, 39, 361–370
364 Effects of ingredients on popcorn popping M. Ceylan and E. Karababa

Table 3 Analysis of variance for responses represent the data for expansion volume and
unpopped kernel ratio in both popping methods.
Sources of Sum of Mean
variation d.f. squares squares F
The lack-of-fit test, which measures the fitness
of the model obtained, did not result in a
Yec significant F-value, indicating that the model is
Regression 14 184.77 13.20 12.33**
sufficiently accurate for predicting the expansion
Residual 11 11.85 1.07
Lack of fit 9 11.41 1.27 5.74 ns volume and kernel ratio for any combination of
Pure error 2 0.44 0.22 ingredient values within the ranges studied.
Total 25 196.62 The large values of the coefficient of determin-
Yuc ation, R2, (Table 2) indicate a good fit of the
Regression 14 110.13 7.86 17.46**
model to the data.
Residual 11 4.96 0.45
Lack of fit 9 4.86 1.54 10.80 ns Salt, vegetable oil, and butter levels showed
Pure error 2 0.10 0.05 statistically significant effects on the unpopped
Total 25 115.09 kernel ratio and expansion volume in conventional
Yem popping, both in linear and squared terms
Regression 14 147.01 10.50 8.97**
(P < 0.05 and 0.01, Table 2). Sodium bicarbon-
Residual 11 12.91 1.17
Lack of fit 9 12.73 1.41 15.60 ns ate levels also had a significant effect on expansion
Pure error 2 0.18 0.09 volume in squared terms. The interactions of
Total 25 159.92 vegetable oil with salt and sodium bicarbonate for
Yum unpopped kernel ratio were significant. Expansion
Regression 14 171.24 12.23 14.91**
volume was affected by the interactions of veget-
Residual 11 9.05 0.82
Lack of fit 9 8.83 0.98 8.72 ns able oil with salt and butter in conventional
Pure error 2 0.22 0.11 popping.
Total 25 180.29 In the case of microwave popping, unpopped
kernel ratio was significantly affected by vegetable
Yec, expansion volume in conventional popping; Yuc,
unpopped kernel ratio in conventional popping; Yem, expan- oil, and butter in the linear term, and salt,
sion volume in microwave popping; Yum, unpopped kernel vegetable oil and butter in the quadratic term.
ratio in microwave popping. Also, interactions of vegetable oil with salt and
*P < 0.05 (14,11) ¼ 2.74; **P < 0.01(14,11) ¼ 4.29; ns, non- butter significantly affected the unpopped kernel
significant.
ratio. For expansion volume, one linear and three
*P < 0.05 (9,2) ¼ 19.38; **P < 0.01(9,2) ¼ 99.38.
quadratic terms of the model were significant, as
were the interactions of salt with each of vegetable
software. The response surfaces for this model oil and butter.
were plotted as a function of two variables while The response surface contour plots showing the
keeping the other two variables at the optimum effects of salt, vegetable oil, sodium bicarbonate
value. Significance was defined as P < 0.05. and butter on unpopped kernel ratio and expan-
sion volume drawn using Statistica software, are
shown in Figs 1–4.
Results and discussion
For microwave popping, expansion volume
Response surfaces for the dependent variables increased with increase in vegetable oil from 0 to
were estimated for both conventional and micro- 10% in the presence of 0–4% salt (Fig. 1), whereas
wave popping methods separately on the basis of unpopped kernel ratio decreased with increasing
the samples in the central composite design. The vegetable oil contents below the medium level
response surfaces showed that it was possible to (coded level 0) of vegetable oil (10%) for all salt
study the effects of changes in the added ingredi- concentrations (Fig. 2). Addition of more than
ents on the popping methods. The coefficients of 10% vegetable oil decreased expansion volume
the fitted model (eqn 1) are shown in Table 2. and increased unpopped kernel ratio. Lin &
The analysis of variance for all responses is Anantheswaran (1988) reported that in the
presented in Table 3. The analysis of variance presence of salt, increasing amount of oil added
showed that the selected models adequately from 2 to 30% decreased the expansion volume

International Journal of Food Science and Technology 2004, 39, 361–370 Ó 2004 Blackwell Publishing Ltd
 Effects of ingredients on popcorn popping M. Ceylan and E. Karababa 365

)1
Figure 1 Effect of ingredients on expansion volume (mL g ) of popcorn in microwave popping.

and the unpopped kernel ratio remained expansion volume than oil popping over the
unchanged, indicating that there was an interac- moisture range of 8–18%. Expansion volume
tion between salt and oil. They also found that the increased (Fig. 1) and unpopped kernel ratio
sample with salt alone had a significantly higher decreased (Fig. 2) with an increase in butter levels.
expansion volume than the sample with oil alone. Medium levels (4%) of salt and lower than 10%
However, Mohamed et al. (1993) showed that salt vegetable oil increased expansion volume in the
adversely affected expansion volume in microwave presence of high levels of butter. High levels of
popping. In the similar way Metzger et al. (1989) butter also increased expansion volume and
reported that hot air popping produced a larger decreased unpopped kernel ratio in the absence

Ó 2004 Blackwell Publishing Ltd International Journal of Food Science and Technology 2004, 39, 361–370
366 Effects of ingredients on popcorn popping M. Ceylan and E. Karababa

Figure 2 Effect of ingredients on unpopped kernels ratio of popcorn in microwave popping.

of sodium bicarbonate. Sodium bicarbonate had produce a high expansion volume in conventional
negative effects on the microwave popping prop- popping (Fig. 3). Decreasing the salt/vegetable oil
erties. Expansion volume decreased and unpopped concentrations resulted in decreased unpopped
kernel ratio increased with high levels of salt and kernel ratio (Fig. 4). Similar patterns of response
vegetable oil at the high levels of sodium bicar- for salt and butter levels on the expansion volume
bonate in microwave popping (Figs 1 and 2). and unpopped kernel ratio were obtained. Less than
At the medium salt level, the middle of the 10% vegetable oil and more than 10% butter levels
vegetable oil content region was found suitable to increased the expansion volume and decreased the

International Journal of Food Science and Technology 2004, 39, 361–370 Ó 2004 Blackwell Publishing Ltd
 Effects of ingredients on popcorn popping M. Ceylan and E. Karababa 367

)1
Figure 3 Effect of ingredients on expansion volume (mL g ) of popcorn in conventional popping.

unpopped kernel ratio. At the medium sodium Salt, vegetable oil and butter showed similar
bicarbonate level, the levels of the other ingredients effects on the popping characteristics for both
gave high expansion volume. At any sodium bicar- conventional and microwave popping. Sodium
bonate level, medium levels of salt and vegetable oil bicarbonate did not show any significant effects
and high a butter level decreased the unpopped on quality in microwave popping and can
kernel ratio in conventional popping. therefore be excluded from the ingredient com-
The response surface contour plots clearly bination. Singh & Singh (1999) reported the
showed that a moderate level of salt has a same observations. However, a moderate level
desirable effect on popping quality. (0.10%) of sodium bicarbonate positively

Ó 2004 Blackwell Publishing Ltd International Journal of Food Science and Technology 2004, 39, 361–370
368 Effects of ingredients on popcorn popping M. Ceylan and E. Karababa

Figure 4 Effect of ingredients on unpopped kernels ratio of popcorn in conventional popping.

Table 4 Optimum levels of ingre-

Conventional popping Microwave popping dients for maximum expansion
volume and microwave unpopped
Expansion Unpopped Expansion Unpopped
kernels
volume kernel volume kernel
Ingredients (mL g)1) ratio (%) (mL g)1) ratio (%)

Best values 37.3 0.2 33.1 4.2

Salt 3.5 4.1 4.4 3.3
Vegetable oil 6 8.6 5.9 6.7
Sodium bicarbonate 0.105 0.03 0 0.04
Butter 12.9 13.1 16.4 15.0

International Journal of Food Science and Technology 2004, 39, 361–370 Ó 2004 Blackwell Publishing Ltd
 Effects of ingredients on popcorn popping M. Ceylan and E. Karababa 369

affected the expansion volume of the popcorn oil, and 16.4% butter, sodium bicarbonate had no
samples. beneficial effect on popping quality. The optimum
levels of ingredients for conventional popping
were observed around 3.5% salt, 6% vegetable oil,
Optimization of ingredient levels
0.10% sodium bicarbonate and 12.9% butter.
The optimum ingredient levels to yield maximum The microwave popping data reported in this
expansion volume and minimum unpopped kernel study may not be applicable to different micro-
ratio for both popping methods are presented in wave ovens. However this study provides useful
Table 4. The maximum expansion volume for information about the popping characteristics of
microwave popping was obtained with a medium popcorn when coated with different ingredients.
level of salt, low vegetable oil, high butter level
and absence of sodium bicarbonate. However, a
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