In this study, we designed high fiber cookie recipe without using additives by means of extrusion-based 3D printing. We aimed to relate printing quality and cookie physical properties with dough rheology and dietary fiber content depending on the flour (oat, rye, rice, and carob flour) and fat type (olive oil or butter). The flour choice influenced all cookie quality parameters: baking loss, color, line height and width, and dietary fiber content. Results indicated that lower baking loss and better printing quality were obtained for cookie dough containing olive oil, which had higher viscosity and consistency coefficient compared with dough containing butter. Cookies with olive oil in which part of the oat flour was replaced with rye and carob flour were printed with high accuracy (≥98%), close to the ideal 3D shape. Overall, this study demonstrates the importance of selecting fat and particularly flour, as well as the extrusion rate on the quality and repeatability of 3D-printed cookies.

Millet is an unexploited cereal with potential in the food industry due to its nutritional value and resistance to harsh climate conditions. Nutritious millet byproducts have a potential application in the development of functional cereal products, but require processing in order to improve their physical and nutritional quality. Therefore, we investigated high intensity ultrasound as a pretreatment to increase the amount of freely available bioactives from proso millet bran. We also analysed the effect of high intensity ultrasound on enzymatic browning, water retention and protein digestibility, which are crucial for the utilization in the bakery and pasta industry. A 15 % millet bran suspension in water was treated with 400-W ultrasound probe for 5, 12.5 or 20 min, with the 60, 80 or 100 % amplitude. High intensity ultrasound treatment with 80 % amplitude for 12.5 min improved most significantly the nutritive value; the antioxidant activity measured by FRAP test increased by 15 % (p<0.05), and total phenolic content by 16 % (p<0.05). Still, the impact on the increase of water-soluble and ethanol-insoluble dietary fibre by 38 % was evident after the treatment for 20 min at 100 % amplitude. High intensity ultrasound treatment at 100 % amplitude for 5 min caused the largest improvements in water retention and limited browning of the sample. High intensity ultrasound treatment activated polyphenol oxidase, regardless of the applied heating of the sample. Due to its ambiguous impact on proso millet bran characteristics, the treatment required an optimization, which showed that the optimal pretreatment of a 15 % millet bran suspension in water is at 100 % amplitude for 9.3 min.

Bran can enrich snacks with dietary fibre but contains fructans that trigger symptoms in people with irritable bowel syndrome (IBS). This study aimed to investigate the bioprocessing of wheat and amaranth bran for degrading fructans and its application (at 20% flour-based) in 3D-printed snacks. Bran was bioprocessed with Saccharomyces cerevisiae alone or combined with inulinase, Kluyveromyces marxianus, Limosilactobacillus fermentum, or commercial starter LV1 for 24 h. Fructans, fructose, glucose, and mannitol in the bran were analysed enzymatically. Dough rheology, snack printing precision, shrinkage in baking, texture, colour, and sensory attributes were determined. The fructan content of wheat bran was 2.64% dry weight, and in amaranth bran, it was 0.96% dry weight. Bioprocessing reduced fructan content (up to 93%) depending on the bran type and bioprocessing agent, while fructose and mannitol remained below the cut-off value for IBS patients. Bran bioprocessing increased the complex viscosity and yield stress of dough (by up to 43 and 183%, respectively) in addition to printing precision (by up to 13%), while it lessened shrinkage in baking (by 20–69%) and the hardness of the snacks (by 20%). The intensity of snack sensory attributes depended on the bran type and bioprocessing agent, but the liking (“neither like nor dislike”) was similar between samples. In conclusion, snacks can be enriched with fibre while remaining low in fructans by applying bioprocessed wheat or amaranth bran and 3D printing.