Understanding the functionality and manufacturing of nixtamalized maize products

© 2021Maize kernels, lime and water are the fundamental materials for manufacturing nixtamalized foods. Processing wise, mature kernels are lime-cooked into nixtamal, then ground into a cohesive dough (masa) and finally processed into traditional and industrialized products, chiefly tortillas and chips. Tortillas are the most relevant food in Mexico and Latin American countries whereas chips the second most relevant savory snack worldwide. These are obtained from three major processes: traditional, industrial fresh masa and dry masa flour from regular and specialty types like blue, quality protein, high-oil, cacahuacintle and nutritionally-enhanced. Emerging technologies have been developed to cook masa and bake tortillas. Lime-cooking is varied according to kernel properties and controlled to optimize starch gelatinization, which influences nixtamal water uptake. Stone-grinding is critical because the attrition further gelatinizes starch affecting dough properties and is controlled to obtain the desired particle size distribution, which considerably differs between tortillas and snacks. Tortilla baking influences rollability and enhances color and flavor whereas frying of snacks the water-oil mass exchange inducing crispiness, color and flavor. This paper reviews the functionality of ingredients, physicochemical changes incurred during processing and the current state of nixtamalized processes for table tortillas and snacks produced from regular and specialty maize types.