Extrusion technology for developing healthy plant-based protein-rich snacks

Overview

This solution leverages extrusion technology to create healthy, ready-to-eat plant-based snacks that replace traditional puffed products associated with low nutritional value. As consumers increasingly prioritize ethics, health, and environmental sustainability, plant-protein-rich snacks represent a growing market opportunity. The research center at São Paulo State University (UNESP) combines food processing expertise with comprehensive physicochemical characterization capabilities to formulate snacks using readily available Brazilian ingredients such as cassava and potato starch, alongside protein sources including Caupi bean, pea, lentil, and chickpeas.

Technical specifications

Core technology and equipment:

• Co-rotating twin-screw extruder with L/D ratio of 40 (Process 11, Thermo Fisher Scientific, Germany) coupled with a modular die
• Differential scanning calorimetry for thermal analysis
• Texturometer for texture profiling
• Static in vitro food digestion following the INFOGEST protocol
• Sensory analysis capabilities
• SDS-PAGE and mass spectroscopy for protein characterization

Research approach:

• Experimental design methodology optimizing extrusion process parameters
• Blending of pea, lentil, and chickpea proteins to enhance amino acid profiles
• Characterization of amino acid composition, starch-protein interactions, and gastrointestinal behavior
• Consumer acceptability evaluation of final formulations

Key applications:

• Ready-to-eat snack products with improved nutritional profiles
• Plant-based protein alternatives for health-conscious markets
• Sustainable food products utilizing regionally available ingredients

Technology readiness level

The technology is at an early-to-mid stage of development. The research center possesses established extrusion processing infrastructure and validated characterization protocols. Future validation will focus on optimizing formulations through systematic experimental design, characterizing nutritional and functional properties, and confirming consumer acceptability. The team seeks collaboration to advance formulation development and move toward pilot-scale validation and eventual commercialization of plant-based extruded snack products.