Extrusion technology for developing healthy plant-based protein snacks
Novel extrusion-based process for producing ready-to-eat, nutrient-dense snacks from plant proteins such as cowpea bean, pea, lentil, and chickpea. Targets the growing demand for sustainable, high-protein alternatives to traditional puffed carbohydrate snacks, with full physicochemical, nutritional, and sensory validation.
Overview
This solution applies twin-screw extrusion technology to transform underutilized plant proteins into ready-to-eat, nutrient-dense snacks. The approach directly responds to shifting consumer preferences toward ethical, health-conscious, and environmentally sustainable diets by replacing traditional puffed snacks, which are typically high in carbohydrates and fat, with formulations rich in plant-based protein. The offering combines food processing expertise with comprehensive physicochemical, nutritional, and sensory characterization to deliver snacks with improved amino acid profiles and consumer acceptability.
Technical specifications
Core capabilities and features:
- Co-rotating twin-screw extruder (L/D 40, Process 11, Thermo Fisher Scientific) coupled with a modular die for flexible snack shaping
- Formulation expertise using locally available Brazilian ingredients, including cassava and potato starch combined with cowpea bean protein
- Blending of pea, lentil, and chickpea proteins to optimize amino acid composition
- Experimental design-driven optimization of extrusion process parameters
- In vitro gastrointestinal digestion analysis using the INFOGEST protocol to evaluate nutrient behavior
- Differential scanning calorimetry for thermal characterization of starch and protein interactions
- Texturometer analysis for mechanical and textural properties
- SDS-PAGE and mass spectroscopy for protein profiling
- Sensory analysis to validate consumer acceptability
Technology readiness level
The research team is currently advancing formulation development and process optimization, with planned validation covering amino acid profiling, starch-protein interaction analysis, gastrointestinal behavior, and consumer acceptability testing. The underlying extrusion infrastructure and analytical capabilities are established and operational, positioning the project to progress from laboratory-scale formulation toward prototype development and pilot validation.
About São Paulo State University
São Paulo State University (UNESP) is a comprehensive public research university with a statewide, multi-campus footprint across São Paulo and a strong applied-research culture. Co-located clinical and veterinary teaching hospitals, field stations, and specialized labs enable translational work and access to real-world testbeds. Its campuses sit near Brazil’s highest-density industrial corridor, connecting partners to suppliers, technology parks, and talent pipelines across metropolitan and interior regions. Research is supported by competitive funding from FAPESP, CNPq, CAPES, and FINEP, alongside industry-sponsored contracts. A dedicated innovation and technology transfer office provides IP management, licensing, startup support, and streamlined pathways for contract research and collaboration.
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