Physicochemical and Techno-Functional Properties of Extruded Corn Starch Snacks Enriched with Huitlacoche (Ustilago maydis): Effects of Extrusion Parameters and Process Optimization

The main objective of this research was to evaluate the effect of extrusion temperature (ET), feed moisture content (FMC), and the proportion of huitlacoche relative to corn starch (HCP/Starch) on the physicochemical, techno-functional, and color properties of an extruded snack, using response surface methodology to optimize processing conditions and product quality. A Box–Behnken design and response surface methodology were used to model and optimize the process. The responses analyzed included residence time (RT), specific mechanical energy (SME), expansion index (EI), bulk density (BD), texture (Tex), water absorption index (WAI), water solubility index (WSI), pH, and color parameters (L*, a*, b*, C*, h°, and ΔE). Results showed that the huitlacoche proportion significantly affected BD, Tex, WSI, and color, while ET and FMC mainly influenced EI, SME, and other techno-functional traits. Multi-response optimization indicated that 150.4 °C, 15.8 g/100 g FMC, and 10–20 g/100 g HCP/Starch maximized EI (2.27) and minimized BD (0.40 g/cm3), Tex (17.5 N), and SME (347.6 J/g). The overall performance was summarized by global desirability (0.83–0.88), a metric that combines all responses into a single scale (0 = poor; 1 = is the most desired goal). The optimized conditions produced snacks with acceptable hydration capacity, pH, and color, supporting huitlacoche as a viable functional ingredient. These findings demonstrate the potential of this traditional resource for developing sustainable, value-added, and health-oriented extruded foods.