Abstract
Driven by the growing demand for flavor diversification in the global craft beer market, conventional drum roasting for specialty malt faces limitations in time consumption and flavor retention. This study aimed to explore explosive puffing as a novel approach for specialty malt production. Base barley malt was treated via explosive puffing at 0.8 MPa to prepare puffed specialty malt, followed by comprehensive characterization of its physicochemical properties, volatile profile, and antioxidant activity, with brewing trials conducted at 15% grist substitution. Results showed that puffed malt reached a color of 183.15 EBC, with formation of roasted pyrazines and caramel-like furans, and a nearly 3-fold increase in total phenolic content and antioxidant capacity. At 15% addition, the puffed malt maintained wort free amino nitrogen and reducing sugar levels, while significantly enhancing beer color, roasted aroma, and antioxidant activity. These findings demonstrate that explosive puffing is a promising alternative to conventional roasting for producing specialty malt.