Investigation of the effects of variable process conditions on the production of Apple snacks by explosion puffing drying

The response surface method (RSM) was used to evaluate the conditions for producing apple snacks using explosion puffing drying (EPD). Independent variables included puffing temperature, pressure difference time, puffing pressure, and moisture content. The measured responses were the rehydration ratio (RR), expansion ratio (ER), total phenolic content (TPC), and total antioxidant activity (TAA). The model explained over 85% of the variations in these responses based on EPD conditions. It is crucial to preserve the bioactive components and structural properties of dried products. ANOVA results and response surface curves indicated that the EPD parameters significantly impacted the structural and bioactive properties. Increased puffing temperature and pressure formed more pores in the product, enhancing RR, ER, TPC, and phenolic acid release. EPD showed remarkable advantages over hot air drying in improving both the drying process and product. The optimal conditions for maximizing the structural and bioactive properties of apple snacks were determined as a puffing temperature of 64.44 degrees C, pressure difference time of 10.55 min, puffing pressure of 2.79 MPa, and moisture content of 48.13%. To our knowledge, no optimization study has examined the effects of system conditions on both structural properties and bioactive components in the production of apple snacks with EPD. Given its benefits for product quality, EPD is recommended for industrial application.