Particle Size as an Indicator of Wheat Flour Quality: A Review

Abstract

Wheat flour is one of the most important food raw materials, with its quality determined by various indicators. One such indicator is particle size and granulometric distribution. In recent years, numerous studies have focused on the effect of flour and bran particle size on the properties of cereal products such as bread, pasta, noodles, and cookies. The aim of this review was to analyze the extent to which this parameter influences the properties of these cereal products. Additionally, the relationships between flour particle size and its chemical composition were presented. Key factors affecting the granulometric composition of flour, related to wheat grain properties and the grinding process, were also discussed. The study specifically focuses on research conducted in the last five years.

1. Introduction

Wheat is among the most important and vital agricultural crops worldwide. Global wheat production is estimated at approximately 770 million tons [1]. Throughout the world, wheat provides around 55% of the carbohydrates and 21% of the total calories consumed in the human diet [2]. Wheat grain is used mainly for food purposes, serving as a key ingredient in various cereal-based products such as bread, confectionery, pasta, groats, and flakes. It also serves as a valuable feed resource, particularly for poultry and pigs [3]. The consumption of wheat-based products provides mainly carbohydrates (about 72%) and proteins (from 10 to 18%), and in particular, wholegrain wheat products and wheat bran are a good source of dietary fiber and other bioactive compounds such as phenolic acids (with trans-ferulic acid accounting for more than 90% of the total phenolic acid [4]), flavonoids, vitamins (especially riboflavin, niacin, alpha-tocopherol, and thiamine), lignans, bioactive peptides, and alkylresorcinols [5]. Wheat is also a good source of minerals such as copper, magnesium, zinc, iron, and potassium [6]. Additionally, wheat is utilized in the production of starch, gluten, brewing malt [7], and bioethanol [8]. The technological value of wheat flour is determined by its physicochemical properties, particularly the protein content and quality, the presence of mineral substances, the content and activity of enzymes, the degree of starch damage [2] and grain hardness [9], and particle size (PS) distribution [10].

Size reduction is one of the fundamental processes in the processing of wheat grain. This process is significant both from a technological [11] and a nutritional perspective [12,13]. Grinding increases the surface area of the particles, facilitating a range of subsequent processing steps by enhancing the contact between the raw material and various factors [14]. Moreover, wheat flour grinding allows for the separation of bran from the endosperm and consequently affects the appearance and texture characteristics of the final products. This process is particularly complex during grain flour grinding, as it occurs in multiple stages and allows for the composition of flour that varies not only in granulometric composition but also in chemical composition [15,16]. Finer particles can influence the smoothness, softness, or crispness of the final product, which is crucial for products such as bread, pasta, cookies, and snacks [17]. On the other hand, reducing PS leads to increased energy consumption for grinding, and this relationship is not linear [18]. As PS decreases, it becomes increasingly difficult to further reduce the size, which leads to a non-linear increase in energy consumption, particularly for particles smaller than 1 mm [19]. Grinding often requires significant amounts of energy to reduce PSs to very small dimensions. Energy consumption in grain grinding can be reduced through various methods, including modifying the properties of the raw material, such as lowering its moisture content or wheat debranning [20,21]. Conversely, adding water to grains before grinding is commonly practiced due to the need to separate the bran layer from the endosperm via sifting. Hydrated bran is more pliable compared to the brittle floury endosperm and results in larger particles upon grinding, which can be relatively easily separated [22,23].

In light of advancements in the wheat grinding process, this paper aims to discuss the impact of wheat flour PS on the properties of final products. Key factors influencing the granulometric distribution of flour, related to wheat grain properties and the grinding process, are also discussed. In particular, publications from the last five years were considered, using databases such as Web of Science, Scopus, and Google Scholar.

2. Factors Influencing the PS Distribution of Wheat Flour

Both the grinding conditions and the properties of the grain being ground determine the wheat grinding process, influencing the PS distribution (Figure 1). The grain industry typically uses a sieve shaker as the primary method for analyzing the PS distribution of wheat flour. However, this method is inaccurate, especially for fine particles below 100 microns, as it causes sieving problems due to particle agglomeration resulting from the cohesiveness of small wheat flour particles and the clogging of sieve holes. This issue is particularly pronounced when flour from soft wheat is analyzed [24]. For the analysis and distribution of fine particles, the laser diffraction method is particularly suitable [25,26].

2.1. Wheat Grinding Process

In the grinding of cereal grains into various types of refined flour, the aim is to separate the bran and germ from the endosperm. This process is complicated and consists of several grinding stages, referred to as grinding passages. It enables the production of various types of refined flour, typically with PSs below 200 µm, which differ in chemical composition and properties, despite being made from the same wheat variety or batch [27]. While various types of grinders can be used for refined flour production, roller mills and stone mills are the most commonly employed. The stone grinding method, in particular, is suitable for producing wholegrain flour [28], as is the production of this type of flour using impact mills [29]. Both the PS distribution of the flour and its properties are influenced by grinding conditions [30], as well as the characteristics of the grain, particularly its mechanical properties [15]. Intensification of the grinding process leads to smaller PSs and requires significant energy input. The heat generated during this process, due to friction, may negatively affect the technological properties of the flour, causing protein denaturation, starch damage, and oxidation of unsaturated fatty acids [31]. This phenomenon occurs primarily during the grinding of grain using stone mills and high-speed impact mills. However, the surface temperature of rollers in roller mills can also rise to 60–80 °C during intensive grinding, which may negatively affect the properties of the flour [28]. Increasingly, in addition to classical methods of grinding plant materials, ultra-fine grinding is being applied [32,33]. This method is particularly recommended for grinding anatomical parts of cereal grains with high fiber content, such as bran [34]. During ultra-fine grinding, particles, typically flour, are produced with sizes below 50 μm [35], using equipment such as jet mills, ball mills, or hammer mills [36,37]. The objective of ultrafine grinding is to produce flour with significantly reduced PSs, thereby enhancing its functional properties and antioxidant properties [38,39,40]. For example, ultrafine wheat flour and bran can exhibit improved water absorption capacity [41], superior dough characteristics, and heightened nutrient bioavailability [34,42]. Additionally, this process can modify the texture, appearance, and sensory attributes of food products made from the flour [43]. This method allows for the production of flour with unique properties, which can be utilized in various technologies [32]. Nevertheless, similar to conventional grinding methods, ultrafine grinding poses a risk of heat generation, which, if not adequately controlled, may adversely affect the protein, starch, and lipid components of the wheat. Detailed information about this technique and the equipment used has been presented by Dhiman and Prabhakar [37].

2.2. Grain Hardness

Among the mechanical properties of wheat, kernel hardness plays a significant role in determining the size and granulometric composition of the particles produced during grinding. Kernel hardness is typically defined as the force required to crush a wheat grain. The hardness of the wheat endosperm is primarily influenced by the adhesion strength between the molecules constituting the endosperm, particularly the bond strength between starch granules and the surrounding protein matrix. As a genetic factor, kernel hardness accounts for over 60% of its variation [44]. The two genes responsible for the soft kernel phenotype in common wheat, Puroindoline a and Puroindoline b, located on the 5D chromosome, are absent in durum wheat, resulting in its hard-textured phenotype [45]. Puroindoline a (PINA) and Puroindoline b (PINB) together form a protein complex known as friabilin, which is responsible for grain softness. Wheat varieties containing this protein exhibit a softer endosperm and break into finer particles more readily during grinding, compared to varieties with a harder endosperm [46]. One of the indirect methods for assessing wheat grain hardness included in the standards of the American Association of Cereal Chemists (AACC) is the method based on the PS index (PSI) (method 55-30.01 Particle Size Index for Wheat Hardness). This method assesses the relative hardness of a wheat grain sample by measuring the PSI after grinding and sieving. PSI is expressed as a percentage, with lower values representing a harder kernel texture, while higher values indicate a softer texture of endosperm [47]. Typically, a sieve with a mesh size of 75 µm is used for this measurement [48]. The PS distribution, particularly for flour obtained from soft wheat, is bimodal, with the first peak occurring at particles sized 20–25 µm [49]. It is also important to note that wheat varieties with a hard endosperm produce a higher proportion of particles with damaged starch granules during grinding, compared to varieties with a soft endosperm [50]. Antoine et al. demonstrated that the hardness of wheat grain is primarily determined by the structure of the endosperm rather than the bran layer [51]. They did not find significant differences in the mechanical properties of the fruit-seed coat between durum wheat and soft common wheat. The bran layer is much harder to grind than the endosperm, which is why it can be easily separated from light flour particles through sieve separation.

2.3. Moisture Content, Grain Temperature, and Other Factors

The moisture content of the grain is a critical parameter that influences both the PS distribution of the flour and flour yield [52]. Kernel failure strength, brittleness, and Young’s modulus (modulus of elasticity) are strongly correlated with grain water content [53]. Moreover, different anatomical parts of the wheat grain (endosperm, bran, and germ) exhibit varying degrees of susceptibility to grinding [54]. Grain conditioning (tempering) prior to grinding, which involves moisture addition, further accentuates the mechanical differences between these parts, thereby significantly affecting the granulometric composition of the particles. The endosperm breaks down into much finer particles compared to the bran and germ. The moistened bran layers are more plastic than the brittle starchy endosperm and, as a result of grinding, produce larger particles that can be relatively easily separated from the endosperm [24]. To ensure optimal grinding conditions, and consequently the desired PS distribution and purity (absence of fine bran and germ fragments) of the endosperm particles, the moisture content of the grain destined for grinding should range between 15 and 17%. Higher moisture levels are typically applied to wheat varieties with harder endosperm [55]. Grinding grain with reduced moisture content in the range of 5–6% leads to an increase in the brittleness of the bran and germ, thus significantly facilitating the reduction of their PSs, which is particularly advantageous in the production of wholemeal flour [56]. Higher grain moisture content requires greater energy input for grinding and results in a lower degree of particle fragmentation [57,58]. For many raw materials and food products, water acts as a plasticizer. The addition of water affects the mechanical properties of the grain, increasing its plasticity, elasticity, and softness, while reducing its brittleness. Consequently, grinding becomes less efficient, as most of the energy supplied during the grinding process is used for plastic–elastic deformations of the material [59]. On the other hand, during the grinding of grain for white flour, grain moistening, known as conditioning or tempering, is beneficial because it significantly increases the plasticity of the fruit-seed coat, which, during grinding, is reduced to larger particles and can be easily separated by sieving from the brittle endosperm fraction. This enables the production of flour that consists primarily of endosperm particles [60]. Hemery et al. [61] demonstrated that as the moisture content of wheat grain increases (9–21%), the extensibility of the fruit-seed coat also increases, thereby reducing its susceptibility to grinding.

The temperature of the grain also affects the grinding process and especially the bran grinding pattern. In particular, the fruit-seed coat can be ground into finer particles if it is frozen prior to this process. Lowering the temperature of the coat below the glass transition temperature (−46 °C) decreases its elasticity and increases its brittleness, making it easier to grind into fine particles [62]. Furthermore, it has been established that wet grinding of wheat bran is more effective in reducing PS compared to dry grinding, while also producing a more uniform PS distribution [63]. An increase in the temperature of cereal grains during grinding leads to increased plasticity and reduced brittleness, especially of the bran and germ, which typically results in a lower degree of particle fragmentation [53]. This effect is particularly beneficial during grain grinding, as it allows for differentiation in the granulometric composition of the milled particles and facilitates the separation of the bran and germ from the white flour. However, it is important to note that during the grinding process, friction causes an increase in the grain’s temperature. This rise in temperature is particularly detrimental if the grain or flour temperature exceeds 50 °C, as it leads to a reduction in its nutritional properties and a loss of nutritional value [28]. On the other hand, preheating the grain prior to grinding through hot conditioning may have a positive impact on certain properties, improving the microbiological purity of the flour and reducing lipase activation, which beneficially affects the flour’s storage stability [64]. Steam explosion also effectively breaks down the dense structure of wheat bran tissues [65], reducing its grinding energy requirements and decreasing PS. As a result, both the yield and the rate of cell wall disruption in the wheat bran flour are increased [66].

The granulometric composition of flour is also influenced by grain characteristics such as the degree of endosperm filling in the kernels [67]. Shrunken kernels, in which the ratio of endosperm to bran is significantly lower than in well-developed kernels, are more difficult to mill, resulting in a smaller proportion of fine particles and a higher proportion of less-milled bran particles. Additionally, morphological traits of the grain, such as test weight and kernel density, show a positive correlation with the proportion of endosperm particles in the flour [68].

3. Effect of PS on the Chemical Properties of Flour

It is important to consider that sorting flour into different size fractions of wheat flour using sifter of air classification causes these fractions to differ not only in PS but also in chemical composition [69,70], which may lead to erroneous conclusions about the influence of PS on the technological and health-promoting properties of flour. Lin et al. [71] used sieving to divide flour obtained from a blend of three wheat varieties into eight size fractions with median PSs (d₅₀) ranging from 13.6 to 42.4 µm. They demonstrated that as the PS of the flour decreased, the starch content and its degree of starch damage increased. Conversely, the lowest protein content was observed in the fraction with a d₅₀ of 17.3 µm, while the highest protein content was found in the fraction with a d₅₀ of 26.3 µm. Furthermore, the flours not only varied in protein content but also in protein type. The finest flour fractions exhibited the highest amounts of albumins, gliadins, and glutenins. Similarly, other researchers, employing sieve classification of white flour into different size fractions (<125, 125–150, and 150–180 µm), noted that flour with finer granulation (<125 µm) displayed the highest protein content [72]. They also found that this fraction showed the lowest ash content and amylolytic enzyme activity (as indicated by the highest falling number) compared to the other fractions. In contrast, other authors observed that in the case of wholegrain flour, sieve segregation into various size fractions yielded an inverse relationship, with the coarsest particles (ranging from 430 to 1180 µm) exhibiting the highest protein content, while the finest fraction (below 80 µm) showed the lowest protein content [16]. These differences arise from the varying susceptibility of different parts of the wheat endosperm to grinding, as well as the heterogeneous distribution of individual grain components within the endosperm. The ash content exhibited a similar trend in relation to flour granulation as observed in white flour, decreasing with increasing PS [16]. Thus, it can be concluded that subjecting flour to PS classification through sieving or air separation [34] results in fractions with differing chemical compositions and, consequently, varying technological applicability. A somewhat different scenario arises when producing size fractions of flour due to the intensification of the grinding process; in such cases, the differences in chemical composition among the flour fractions are minimal [70]. In this context, the influence of PS on the technological usability of flour is predominant.

Furthermore, the PS of flour influences the extraction rate of phenolic compounds within the flour. Memon et al. [16] used sieving to divide wholegrain wheat flour into various PS fractions ranging from below 80 µm to 1180 µm and found that the coarsest PS class (430–1180 µm) exhibited the highest content of phenolic compounds, particularly ferulic acid. Conversely, the fraction smaller than 80 µm was the least enriched in these compounds. The extractability of phenolic compounds increased with the degree of flour grinding. These differences are likely to be attributed to variations in the flour composition, especially regarding the content of fruit and seed coats rich in phenolic compounds, which, due to the grinding process, yielded the greatest quantity of coarse particles. In a different scenario, Brewer et al. [14] and He et al. [73] observed that when grinding wheat bran into different PS fractions, the content of bioactive compounds and antioxidant activity increased with the extent of grinding. A similar trend was noted by Bressiani et al. [54], who produced various PS fractions of wholegrain flour by intensifying the grinding process without sorting the flour into fractions. Similar relationships were reported by other authors [74], who also demonstrated that as the degree of grinding increased, the bioaccessibility of bran improved. Therefore, it can be concluded that the method of obtaining flour fractions with varying PSs significantly impacts their antioxidant properties and the extractability of phenolic compounds. Generally, the intensification of the grinding process leads to the production of finer flour particles with higher extractability of phenolic compounds. However, during ultrafine grinding, considerable heat generation may occur, potentially negatively affecting antioxidant activity and the content of these compounds in the flour [14].

4. Wheat Flour PS and Cereal-Based Product Quality

Many researchers have shown that the PS of flour or bran has a significant impact on the sensory acceptance and physical properties of different cereal products (Figure 2). This chapter discusses the influence of PS on the quality characteristics of the most popular cereal products.

4.1. Bread

Numerous researchers have demonstrated the relationship between the PS distribution of flour and the properties of bread, pasta, noodles, and cookies. In recent years, several studies have addressed this topic. These studies particularly pertain to wholegrain flour or flour obtained from ground bran [75]. Such flour is a valuable source of fiber and numerous bioactive compounds, which have been documented to exhibit health-promoting effects [76]. Bressiani et al. [54] analyzed the impact of wholegrain flour PS on the physicochemical properties of flour, dough, and bread. The authors used a laboratory impact mill with a cooled chamber to produce the wholegrain flour (

Table 1. Influence of wheat flour PS on the quality of wheat products.

Kind of Flour	Median Particles or Range of Class [µm]	Kind of Mill	Effect on Product Quality	Ref.
Bread
WG	195, 608, 830	Laboratory impact mill with cooling chamber	Bread with the greatest volume and the lowest crumb hardness was produced from flour with medium-sized particles (608 µm). Flour with the coarsest grinding resulted in the poorest baking quality.	[54]
WG	199, 450, 1315	Pulverizing machine	The highest quality bread was made from flour with the finest degree of grinding, resulting in the greatest volume and the softest crumb.	[77]
WF with BR	BR: 162–257, 162–360, 162–485, 162–257	Roller grinding (industrial mill)	The bread with the best texture and highest rise was made from flour with the finest PS, resulting in the greatest volume and softest crumb. However, the inclusion of finely ground bran led to a reduction in volume and an increase in the bread’s hardness.	[79]
WF with BR	BR: 11.3, 60.4, 362.3	Superfine grinding pulverizer	The bread with the best sensory evaluation and highest antioxidant activity was obtained from the finest bran fraction. However, a reduction in loaf volume and an increase in bread hardness were observed.	[40]
WF	52, 66, 78, 88, 109	Roller mill	The quality of steamed bread deteriorated as PS decreased, leading to lower volume, increased hardness, and reduced sensory acceptability.	[80]
Pasta and noodles
WF	17–385	Hammer mill	Decreased PS resulted in increased hardness, gumminess, and cooking losses of the noodles.	[81]
WF	52–109	Roller mill	Reducing the PS resulted in higher levels of hardness, gumminess, and cooking losses in the noodles.	[82]
WF	85–110, 110–132, 132–193	Roller mill	The highest cooking losses, cutting stress, resistance to compression, and firmness were observed in noodles produced from the finest particle fractions.	[83]
WS with BR	BR (<180–1497)	Roller mill and disc mill	Pasta with higher firmness, less stickiness, and lower cooking losses was produced when fine bran particles were added.	[84]
WS with BR	160–431, 420–1.000, 500–2.000	Not included; bran was fractionated by sieving	Noodles with coarse bran exhibited the lowest hardness, while the highest sensory scores were obtained for noodles made with the finest bran fraction.	[85]
WF	62, 68, 80, 91, 115, 224	Roller mill	Noodles with higher firmness and springiness and lower cooking losses were produced from flour with fine PS.	[86]
WF	d90: 55.8, 66.8, 103.0	Roller mill and hammer mill	Noodles produced with the finest flour exhibited lower cooking losses and greater firmness and springiness.	[87]
Cookies
WF	>150; 100–150; <100	Laboratory roller mill Chopin	There was a negative effect, particularly from the smallest particles (<100 µm), on the quality of cookies, including hardness, diameter, and spread ratio.	[88]
WF	83, 643, 999, 1036	Roller mill	Higher quality and lower susceptibility of starch to in vitro digestion were observed in cookies made with coarser particle fractions.	[89]
WF and WM	WF: 67 WG: 17, 29, 53, 84	Jet mill	The best quality cookies were obtained from WF. Replacement of WF with WG caused harder and darker cookies.	[90]
WF	>180, 150–180, <150	Not included; wheat flour was fractionated by sieving	A decrease in hardness and an increase in brittleness of the cookies were noted as PS decreased.	[91]

WG—wholegrain flour, WF—white refined flour, WS—semolina, BR—bran.

). They found that wet gluten yield, starch damage, and flour water absorption increased with finer grinding. Additionally, the physical properties of the dough were weakened, with reductions in dough mixing tolerance, extensibility, and viscosity observed. The highest quality bread, in terms of volume and firmness, was produced using flour with a PS of 609.4 µm. Similarly, other authors have analyzed the baking properties and quality characteristics of wheat bread produced from wholemeal flour fragmented to varying degrees (average PSs of 199, 450, and 1315 µm) [77]. However, their results differed significantly from the data reported in the previous study [54]. Despite the fact that an increase in the degree of flour fragmentation also led to greater starch damage and water absorption, no weakening of the dough structure occurred during kneading. Furthermore, the highest volume and softest crumb were obtained from the finest flour particles, which is contrary to the findings of the study [54]. This indicates that, in addition to PS, other factors contribute to bread quality. One such factor could be the quantity and quality of wet gluten, which also has a fundamental influence on the characteristics of bread and is often used as a natural flour improver, increasing volume, improving texture, and reducing baking losses [78].

Other researchers [40] analyzed the impact of bran with varying degrees of PS on the quality characteristics of wheat bread. They demonstrated that the most finely ground bran (with a median PS of 11.3 µm) delayed the staling process of the bread. However, at all PSs, there was a reduction in loaf volume and an increase in crumb hardness. The smallest reduction in loaf volume was observed for the coarsest bran fraction (median PS of 362.3 µm). The reduction in bread volume was directly proportional to the bran content in the recipe. Moreover, bread enriched with the finest bran fraction received the highest ratings in consumer evaluations. The use of ultra-finely ground bran produced bread with better taste, texture, and overall palatability compared to bread with larger bran particles.

Lapčíková et al. [79] analyzed the baking properties of white flour with varying granulation, obtained directly from the mill. They found that, with a similar chemical composition, fine flour (in the range of 162 to 257 µm) exhibited higher water absorption compared to coarser flour fractions ranging from 162 to 360 µm (semi-coarse) and from 162 to 485 µm (coarse). Additionally, the finer flour showed greater dough elasticity. Moreover, white flour enriched with bran from the finest fraction of white flour (fine) showed the highest water absorption and similar extensibility to the other white flour fractions. However, this did not translate into the volume of the bread, which was greatest for bread made from the finest fraction of white flour (without bran addition). This bread also exhibited the lowest crumb hardness. Conversely, bread made from flour enriched with bran had the lowest volume and the highest hardness. This demonstrates that, for the same granulation of wheat flour, its chemical composition—particularly the bran content—plays a fundamental role in bread quality [92]. On one hand, bran enriches bread with fiber, minerals, and bioactive compounds. On the other hand, it adversely affects the gluten matrix, weakening and disrupting it [93]. This results in products with greater hardness due to a denser and more compact crumb structure, often stemming from the lower volume of the products [79,94].

The PS of flour also influences the properties of steamed bread. Pang et al. [80] used white wheat flour with varying degrees of PS (ranging from 52 to 109 µm) in the production of steamed bread. They demonstrated that smaller flour PSs had a favorable effect on increasing the disulfide bond content, which positively impacted the dough’s rheological properties, leading to better gluten development and strengthening. This, in turn, resulted in improved baking outcomes, such as higher loaf volume and softer crumb texture. However, consumer evaluations showed that products made from flour with medium PS (66 and 78 µm) were the most acceptable, primarily due to the highest ratings for crumb elasticity. Additionally, bread made from the finest flour, despite having the smallest loaf volume, exhibited the lightest color. On the other hand, other studies have shown that, in the case of whole grain flour, a higher degree of particle fineness is associated with a darker color of the crumb and the bread, primarily due to the dilution of the starchy endosperm [95]. These results are inconsistent with those obtained for conventionally baked wheat bread [79], where the highest loaf volume was achieved with the finest flour. This discrepancy is likely due to the much coarser granulation (average PS of 162–257 µm) of the flour used in traditional bread production compared to that used for steamed bread. It confirms that excessively fine flour PSs may negatively affect bread quality. In contrast, other researchers found that, in the case of flour made from stale bread and reused for bread production, PS had little impact on its baking properties [96].

To summarize this chapter, it should be noted that not only PS but also their composition and structural changes resulting from temperature increases during grinding collectively influence the quality characteristics of bread. Therefore, the granulation of flour cannot be the sole indicator of its suitability for baking.

4.2. Pasta and Noodle Quality

Pasta and noodles, alongside bread, are among the most fundamental cereal products. Typically, particularly in the case of pasta, these products are made from durum wheat grain particles with larger granulation, known as semolina, due to the superior sensory and culinary quality they provide [97,98]. Moreover, numerous pasta manufacturers suggest that semolina with PSs between 250 and 450 μm ensures uniform hydration [99]. However, pasta is also often produced from common wheat flour, which has a much finer granulation [82,100,101,102]. Ma et al. [81] observed that noodles made from finely ground flour exhibited higher water absorption and greater cooking losses compared to products made from coarse flour (Table 1). Similar results were obtained by Guan et al. [82]. It was found that that the starch granules released from noodles primarily account for the losses during pasta cooking [103]. Moreover, noodles produced from the finest particles of flour were firmer and less adhesive than those made from coarse flour, which were characterized by greater softness and elasticity [81]. Similar conclusions regarding noodle texture were reached by other authors [83]. Hatcher et al. [83] analyzed three different fractions of farina-type wheat flour (PS range: 85–193 µm) and their impact on dough and noodle properties. The best textural characteristics, indicated by the highest shear stress, the greatest work required to compress the noodles, and the highest firmness, were observed in products made from the finest particles. Additionally, Hatcher et al. [83] found that the cooking losses increased as the PS of the flour used in production increased. However, the PS of the flour had a relatively minor effect on the amount of water absorbed by the pasta during cooking. Instead, the degree of starch damage had a more significant impact on these characteristics. Higher cooking losses and lower weight gain were observed in products made with farina, exhibiting a greater degree of starch damage, confirming previous research that suggests the degree of starch damage in semolina should be kept as low as possible [104]. Further dependencies were identified by Wang in [86], who analyzed the properties of noodles made from wheat flour with varying degrees of PS reduction, with median PSs ranging from 62 to 224 µm. Similar to the findings in studies [81,103], an increase in the degree of PS reduction correlated with a higher extent of starch damage in the flour. However, they observed an inverse relationship between PS and the hardness of the noodles. In addition, noodles produced from flour with the coarsest granulation exhibited the lowest springiness, and this parameter increased with a decrease in the flour PS, ranging from 81 to 92%. Interestingly, they did not confirm the negative relationship between cooking losses of noodles and flour PS, as noted in the study [81]. The highest losses were recorded for products with the coarsest granulation (PS d₅₀ = 225 µm), while the lowest losses were observed for noodles with median PSs of 68 µm and 80 µm. Furthermore, the water absorption capacity of the product in both studies [81,104] increased as the PS of the flour decreased. Thus, it can be concluded that, in addition to PS, other factors likely influence the culinary properties of noodles, stemming from differences in the chemical composition of the flour used, enzyme activity, or gluten properties.

Other researchers analyzed the quality characteristics of noodles made from three fractions of wheat flour ground to different PSs, expressed by the d₉₀ parameter (90th percentile) [87]. The reduction in flour PS resulted in faster gluten structure formation, stronger dough compactness, and subsequently increased noodle hardness and springiness. Additionally, noodles made from finer flour particles exhibited lower cooking losses. Notably, the study [87] demonstrated that flour PS influences noodle quality characteristics to varying degrees depending on the degree of drying. Different relationships between PS and quality indicators were observed for semi-dried and fine-dried noodles. Other researchers analyzed pasta made from whole wheat flour and white flour derived from the same wheat variety but with different PSs [105]. These flours differed significantly in granulation, particularly in the proportion of the finest (<200 µm) and coarsest (>500 µm) particles. The findings of this study demonstrated wholegrain pasta exhibiting greater hardness and lower water absorption, swelling index, and optimal cooking time compared to pasta made from refined flour. However, there were no significant differences in cooking loss, cohesiveness, or chewiness between the two types of pasta. These results suggest that the presence of bran alters the pasta’s structure by disrupting the gluten–starch matrix. Moreover, the PS of wholegrain flour influenced cooking parameters, including cooking time and water absorption, suggesting that wholegrain pasta made from coarser particles may demonstrate improved quality.

In recent years, some studies have focused on analyzing the impact of adding bran with varying degrees of fineness to pasta or noodles. Steglich et al. [106] produced spaghetti enriched with wheat bran with different median PSs from 90 to 440 μm. They found that flour PS had no effect on the microstructure of cooked spaghetti. However, pasta made from coarser bran particles had a rougher surface. PS did, however, affect the texture of the pasta. Pasta made with the addition of finely ground bran was characterized by greater firmness, as measured by compression force, and it received higher scores in sensory evaluations. Similar findings were reported by other researchers [84], who ground wheat bran into seven fractions with average PSs ranging from <180 to 1497 μm, replacing semolina at levels of 1%, 5%, 10%, and 20% in spaghetti production. Their study observed that, as in the previous study [106], decreasing the PS resulted in increased firmness of the pasta, although this effect was not consistent across all size fractions of the bran. The firmest pasta was obtained by adding bran with the coarsest and finest granulation at a 1% level relative to wheat flour. However, a 20% inclusion of the coarsest bran fraction resulted in the lowest quality pasta, with the least firmness, highest stickiness, and greatest cooking losses. In contrast, pasta made with the same proportion of the finest bran fraction exhibited good culinary properties. The authors explained this trend using microscopic images, which showed that larger bran particles disrupted the gluten network structure, particularly when their proportion in the semolina exceeded 5%. Moreover, the addition of bran flour to semolina resulted in darker-colored pasta, with higher contents of phenolic compounds and phytosterols and increased antioxidant activity in the spaghetti. This increase was primarily proportional to the percentage of bran flour in the pasta. However, no significant influence of bran PS on the bioactive compound content of the pasta was observed. Similar findings were obtained by other researchers studying extruded pasta made from whole wheat flour [105]. Chen et al. [85] analyzed the potential for enriching Chinese noodles with bran of varying PSs. They observed an inverse relationship between the size of added bran particles and noodle hardness. Similarly, the gumminess and chewiness of the noodles decreased as the proportion of larger bran particles increased, which was attributed to the lesser disruption of the gluten structure by finer bran particles. However, the size of the added bran had little impact on noodle cooking time. Overall, the addition of bran to noodles resulted in lower sensory evaluation scores, although finely ground bran allowed for more acceptable products compared to those made with coarse bran, particularly in terms of taste, surface smoothness, and external appearance of the noodles [85].

4.3. Cookies

Another fundamental food product is shortbread cookies, whose popularity among consumers is steadily increasing, primarily due to the use of various health-promoting additives [107]. Barak et al. [88] found that wheat flour with a PS above 150 µm is particularly suitable for this type of product. Flour with finer PSs, in the range of 100–150 µm, as well as flour with particles smaller than 100 µm, exhibited a higher degree of starch damage compared to flour with PSs exceeding 100 µm. Additionally, the finest flour fraction showed the highest amylolytic enzyme activity (indicated by the lowest falling number values). This had a negative impact on the physical properties of the cookies. As flour PS increased, both the diameter and spread ratio of the products increased, while the hardness of the cookies decreased [88] (Table 1). Higher spread ratio values, combined with lower hardness, suggest poorer baking quality of the flour used for shortbread cookies [33]. The authors attributed these changes mainly to the higher water absorption of the finer flour, caused by the greater degree of starch damage. This resulted in a denser dough consistency and less expansion of precuts during baking [88]. Similar relationships were observed by other researchers [89], who found that coarser flour is more suitable for shortbread cookie production than finer flour. They also noted that cookies made from coarser flour exhibited lower starch susceptibility to in vitro digestion. In contrast, Boz reported different findings when analyzing the effect of wheat flour PS on the quality of shortbread cookies [91]. The lowest hardness was observed in cookies made from the finest flour (less than 150 µm), while the highest hardness was found in those made from flour with particles larger than 180 µm. However, the method used to obtain the different flour fractions in Boz’s study differed from that of Barak et al. [90], where wheat flour was ground into different PS fractions. In Boz’s study [91], the flour was sorted into size fractions, and the chemical composition of the flour was not specified. Therefore, the different cookie textures could be attributed to significant differences in the chemical composition of the flour, particularly the protein content. This study did not specify the basic composition of the flour [91]. Sorting flour particles into size fractions leads to particle classes that significantly differ in chemical composition and, thus, in functional properties [41]. Protonotariou et al. [90] investigated the potential use of micronized whole grain wheat flour for shortbread cookie production, with PSs ranging from 17 to 84 µm. They compared the results to a control sample using commercial white flour with an average PS of 67 µm. The control flour produced the highest quality products, characterized by the highest crispness and lowest density. In contrast, replacing wheat flour with micronized whole grain flour resulted in darker, harder products, with hardness increasing as the degree of micronization increased. This effect was particularly disadvantageous in products made entirely from whole grain flour, mainly due to the increased viscosity of the batter as the proportion of micronized whole grain flour in the recipe increased. Additionally, it was demonstrated that when cookies are enriched with other types of flour besides wheat flour, the PS of these flours also affects the quality of the final products, potentially leading to either an improvement or deterioration in their quality characteristics [108,109,110].

5. Conclusions and Future Perspectives

The degree of fineness of wheat flour plays a fundamental role in determining the quality characteristics of final products. Finer grinding not only alters the PS distribution but also affects flour properties such as the starch damage and the amount of free sulfhydryl groups. Furthermore, the intensification of grinding often leads to an increase in flour temperature, which frequently has a negative impact on its processing properties. These factors, along with the increased surface area of particles during cereal product manufacturing, influence both the physical properties of the dough—particularly gluten formation—and the biochemical reactions that occur during its production. These changes directly impact final product attributes such as appearance and texture, which are critical for consumer acceptability and the bioavailability of biologically active compounds. Moreover, dough production parameters are also influenced by flour PS. Both overly fine and overly coarse grinding can negatively affect the properties of cereal-based products. Additionally, finer grinding requires more energy input, leading to higher raw material costs. Therefore, in flour production, it is essential to achieve an optimal degree of grinding suited to the intended application. It is also important to recognize that PS distribution is only one aspect of flour’s technological suitability. A comprehensive analysis, including other properties such as protein content and water absorption capacity, is necessary to make informed decisions about directing specific flour types for particular cereal products. Notably, ultrafine grinding is a technique that can produce wheat flour or bran with unique properties and reduce the fruit-seed coat to very fine particles. Future studies are needed to evaluate the effects of ultrafine grinding on various wheat products and cereal products supplemented with bioactive components, as well as the bioaccessibility and bioavailability of bioactive compounds.