Multivariate modeling platform for plant-protein DX extruded snack development
Predictive modeling service for developing high-quality directly expanded (DX) plant-protein snacks. Combines twin-screw extrusion expertise with multivariate statistical analysis to optimize formulations, process parameters, and product attributes for whole grain, high-protein, and keto snack applications.
Overview
This offering delivers a predictive modeling and extrusion development platform for plant-protein directly expanded (DX) snacks. The approach combines over 100 years of collective extrusion experience with multivariate statistical modeling to predict finished product quality from ingredient composition, extruder setup, and operating conditions. The goal is to enable partners to efficiently develop crunchy, easily dissolvable, low tooth-packing snacks with targeted value propositions such as whole grain, high protein, and keto positioning.
Technical specifications
Extrusion capabilities:
- Clextral Evolum 32 twin-screw extruder with 32 mm screw, 6-barrel configuration, and L/D ratio of 24:1
- Clextral EV 44+ twin-screw extruder with 44 mm screw, 10-barrel configuration, and L/D ratio of 40:1
- Jinan Arrow FT75 twin-screw extruder with 72 mm screw, 7-barrel configuration, and L/D ratio of 28:1
- Production capacity ranging from 110 to 660 lbs per hour
- Ability to test up to 10 formulations per day
Modeling and analysis:
- Aspen Unscrambler software for multivariate analysis using Multiple Linear Regression (MLR), Partial Least Squares Regression (PLSR), and Principal Component Regression (PCR)
- Optimization of L/D ratio, feed rate, moisture content, barrel temperatures, screw speed, screw profile, and die shape
- Measurement of bulk density, color, moisture content, Specific Expansion Index (SEI), and Longitudinal Expansion Index (LEI)
- Assessment of physicochemical, structural, functional, flavor, sensory, rheological, and microscopy characteristics
- Analysis of starch-protein-fibre matrix interactions
Technology readiness level
The platform is operational and ready for client engagement. The integrated facility offers end-to-end capabilities from concept through execution, supported by established partnerships with Clextral, Canadian universities, Pulse Canada, Saskatchewan Pulse Growers, the National Research Council, and analytical laboratories. The modeling framework has been validated through prior extrusion work, and the team is prepared to collaborate on new formulations with the potential for real-time production visibility in future iterations.
About SASKATCHEWAN FOOD INDUSTRY DEVELOPMENT CENTRE
The Saskatchewan Food Industry Development Centre (Food Centre) is a non-profit organization that provides comprehensive services for food development, processing, and commercialization. It operates three facilities in Saskatoon, including the Agri-Food Innovation Centre, the Advanced Food Ingredients Centre, and a pilot plant. The organization employs food scientists and technicians who utilize specialized equipment to assist clients with ingredient validation, extrusion, fermentation, bioengineering, and food safety. By offering contract research, manufacturing, and incubation services, the Food Centre enables businesses to transition from initial concepts to final market-ready products, minimizing technical and manufacturing risks.
Serving a diverse client base ranging from startup agri-businesses to Fortune 500 companies, the Food Centre plays a critical role in strengthening Saskatchewan’s bioeconomy and expanding market opportunities for producers. It addresses industry challenges such as supply chain disruptions and shifting consumer preferences by providing expert technical troubleshooting and infrastructure. With over 25 years of experience, the organization has supported more than 410 clients in developing nearly 950 innovative products, contributing significantly to both the provincial and national economy through its partnership-driven, full-service team approach.
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