Optimization of Processing Parameters and Quality Evaluation of Breakfast Flakes Prepared From Sonicated Corn and Its By‐Products Supplemented With Quinoa Powder

ABSTRACT Corn cob (C) and silk (S), produced in substantial quantities as agro‐waste, are rich in bioactive compounds with disease‐preventive potential. Thermal processing often leads to nutrient degradation. Therefore, this study explored the effect of optimized sonication—a non‐thermal technique with the potential to enhance the bioactive profile and stability—on Grain: G0, G10, G20, G30, Cob: C0, C10, C20, C30; and Silk S0, S10, S20, and S30, from which the best was incorporated into flakes. C 1 (control) with 100% non‐treated corn grain flour (CGF), treatment ( T 1 ; 70:10, T 2 ; 50:30, T 3 ; 30:50, T 4 ; 10 varied SCGF: SCF) and evaluated for moisture, bacterial, and fungal count in a storage period of 4 weeks. The significant result showed (G20 ≥ G0) for protein 15%, DPPH (340 ≥ 320) μg/g, TPC (1115 ≥ 1006) μg/g, and TFC increased 23 μg/g. In (C20), a significant difference was noted in fiber (34.6%–35.4%), TFC (1.05–1.85) μg/g, magnesium (1.88–1.98) μg/g, and vitamin A (188.7–193) μg/g. In S20, protein 2%, fiber 3%, DPPH 20 μg/g, TFC 190 μg/g, iron 6 μg/g, and vitamin A 1560 μg/g increased significantly. Storage of flakes exhibited lower moisture content (8%–10% reduction) and reduced microbial load, with bacterial and fungal counts remaining below detectable limits for 14 days, compared to control flakes which showed early microbial growth. Thus, the use of sonication and corn byproducts offers a cost‐effective, nutrient‐dense, diverse food product and ensures food security.