Optimisation of Extrusion Process Parameters for Producing Combined Breakfast Cereals Using Pumpkin Flour

The extrusion process plays a key role in the production of dry breakfast cereals, providing improved organoleptic properties, structure, and nutritional value. In recent decades, this method has been actively used in the food industry due to its high efficiency and ability to modify the physicochemical characteristics of raw materials. The aim of this study is to optimise the process parameters of extrusion in the production of combined dry breakfast cereals with added pumpkin flour. For this purpose, the Box–Behnken rotational experimental design method and regression analysis were used to assess the effect of temperature (130–170°C), raw material moisture (10%–18%), and screw speed (180–300 rpm) on the quality indicators of the extruded product. At 170°C, a raw material moisture of 18%, and a screw speed of 180–210 rpm, a product with low bulk density, high expansion coefficient, and optimal water absorption and solubility indicators was formed. The best technological characteristics were achieved at 170°C, 18% humidity, and 210 rpm, providing an expansion coefficient of 3.8, a water absorption index of 3.2 g/g, a water solubility index of 2.2%, a bulk density of 0.43 g/cm³, and a β-carotene content of 5.9 mg/100 g. Adding pumpkin flour positively affected the functional value of extrudates, increasing the dietary fibre, β-carotene, and antioxidant contents. However, introducing more than 15% pumpkin decreased the expansion coefficient and increased the bulk density due to changes in the moisture content and viscosity of the mixture. The novelty of the study lies in the scientific substantiation of the optimal extrusion parameters with added pumpkin flour for the development of functional breakfast cereals with improved nutritional and organoleptic characteristics, helping to expand the range of healthy food products.